Installation and Service Instructions for use by heating contractor Vitocrossal 300 CA3 Series 3.5, 4.0, 5.0 and 6.0 Gas condensing boiler with cylinder burners Heating input: 3500 to 6000 MBH (1026 to 1758 kW) VITOCROSSAL 300 Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference. H 5776 774 - 05 09/2016 Please file in Service Binder Safety Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections). For a listing of applicable literature, please see section entitled “Important Regulatory and Safety Requirements”. Warranty Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void. Licensed professional heating contractor The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contractor. Please see section entitled “Important Regulatory and Installation Requirements”. Contaminated air Air contaminated by chemicals can cause by-products in the combustion process, which are poisonous to inhabitants and destructive to Viessmann equipment. For a listing of chemicals which cannot be stored in or near the boiler room, please see subsection entitled “Mechanical room” in the “Installation Instructions”. Advice to owner Once the installation work is complete, the heating contractor must familiarize the system operator/ ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the heating season begins. 2 Carbon monoxide Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon monoxide gas. For information pertaining to the proper installation, adjustment, service and maintenance of this equipment to avoid formation of carbon monoxide, please see subsection entitled “Mechanical room” and “Venting requirements” in the “Installation Instructions”. Fresh air This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist. For information pertaining to the fresh air requirements of this product, please see subsection entitled “Mechanical room” in the “Installation Instructions”. Equipment venting Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning. For information pertaining to venting and chimney requirements, please see section entitled “Venting Connection”. All products of combustion must be safely vented to the outdoors. WARNING Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the boiler contained in this manual. 5776 774 - 05 Product documentation Read all applicable documentation before commencing installation. Store documentation near boiler in a readily accessible location for reference in the future by service personnel. Safety Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Safety, Installation and Warranty Requirements Fiberglass wool and ceramic fiber materials WARNING Inhaling of fiberglass wool and/or ceramic fiber materials is a possible cancer hazard. These materials can also cause respiratory, skin and eye irritation. The state of California has listed the airborne fibers of these materials as a possible cancer hazard through inhalation. When handling these materials, special care must be applied. Suppliers of ceramic fiber products recommend the following first aid measures: - Respiratory tract (nose and throat) irritation: If respiratory tract irritation develops, move the person to a dust free location. - Eye irritation: If eyes become irritated, flush immediately with large amounts of lukewarm water for at least 15 minutes. Eyelids should be held away from the eyeball to ensure thorough rinsing. Do not rub eyes. - Skin irritation: If skin becomes irritated, remove soiled clothing. Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin cream or lotion after washing may be helpful. - Gastrointestinal irritation: If gastrointestinal tract irritation develops, move the person to a dust free environment. Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials: - Avoid breathing fiberglass dust and contact with skin and eyes. - Use NIOSH approved dust/mist respirator. - Wear long-sleeved, loose fitting clothing, gloves and eye protection. - Wash work clothes separately from other clothing. Rinse washer thoroughly. - Operations such as sawing, blowing, tear-out and spraying may generate airborne fiber concentration requiring additional protection. (continued) First aid measures - If eye contact occurs, flush eyes with water to remove dust. If symptoms persist, seek medical attention. - If skin contact occurs, wash affected areas gently with soap and warm water after handling. WARNING Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause serious injury or loss of life and which are known to the State of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. Codes The installation of this unit shall be in accordance with local codes. In the absence of local codes, use: CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning Appliances for Canada. For U.S. installations, use the National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes. In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S., use the National Electrical Code ANSI/ NFPA 70. The heating contractor must also comply with the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 where required by the authority having jurisdiction. Mechanical room Ensure the mechanical room complies with the requirements of the System Design Guidelines and/or Technical Data Manual. In addition, see section entitled “Mechanical Room” on page 11 in this manual. Viessmann recommends installation of an additional electrical disconnect switch and a fuel shut-off valve (if possible) outside the mechanical room or enclosed area of installation. 5776 774 - 05 The maximum room temperature of the mechanical room where the boiler is located must not exceed 104°F (40°C). 3 Table of Contents Vitocrossal 300, CA3-3.5, 4.0, 5.0 and 6.0 Service Page Safety Safety, Installation and Warranty Requirements ............ 2 General Information Important Regulatory and Installation Requirements ........8 About these Installation Instructions ...........................10 Product Information ..................................................10 Mechanical Room .....................................................11 For Retrofit Applications............................................11 4 Recommended Minimum Service Clearance .................12 Unpacking and Placement of Boiler .............................13 Reducing Boiler Height ........................................... 13 Preparing the Boiler ..................................................14 Water Side Connection ........................................... 14 Boiler Connections....................................................15 Electrical Connections............................................ 18 Making the LON Connection ......................................32 Connecting Flue Gas Pipe ..........................................34 Connecting Neutralization System ..............................35 Condensate Connection ............................................36 Gas Connections ......................................................37 Initial System Fill ................................................... 40 General ...................................................................41 System Layout 1 .................................................. 42 System Layout 2 .................................................. 43 Boiler Piping in Heating/Cooling Application .................44 Venting General Venting Information ......................................45 Additional Requirements for Stainless Steel Vent Pipe Material ....................................................48 Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material ....................................................49 Vent Requirements ................................................ 50 Direct Venting (Two Pipe System) ..............................51 Side Wall Venting ................................................. 52 Component Installation Guide .................................. 53 Vent Termination Location Requirements - Vertical .......53 Installation of Support System - PP(s) .........................54 Venting Options - Stainless Steel/ PP(s) Two Pipe System - Vertical Exhaust/ Vertical Air Intake ....................................................55 Two Pipe System - Horizontal Exhaust/ Horizontal Air Intake .................................................57 Two Pipe System - Vertical Exhaust/ Horizontal Air Intake .................................................58 Two Pipe System - Vertical/Horizontal Installations .......58 Single Pipe System - Vertical Exhaust/ Room Air Dependant.................................................59 Single Pipe System - Horizontal Exhaust/ Room Air Dependant.................................................60 Multiple Boiler Installations ..................................... 61 General Service Information Service Equipment ....................................................62 Important Regulatory and Installation Requirements ......63 Safety Instructions ................................................ 64 Filling the Heating System with Water and Ventilating .. 66 Filling Condensate Trap with Water ............................66 Checking the Type of Gas .........................................66 5776 774 - 05 Boiler Installation Vitocrossal 300, CA3-3.5, 4.0, 5.0 and 6.0 Service Table of Contents Page Service Operating the System........................................... 67 Adjusting the Heating Curve ......................................70 Integrating the Control Unit into the LON.....................72 Setting the Boiler Sequence .......................................73 Preparing for Service Work on the Boiler and Burner .....74 Reducing Operational Output (if required) ....................75 Checking Static and Connection Pressure ....................76 Checking the Rotary Slide Valve Setting ......................77 Measuring CO2 Content ............................................79 Displaying Ionization Current .................................... 81 Turning the System Off.............................................81 Dismantling the Burner........................................ 82 Burner Control Unit .................................................. 84 Coding Card on Burner Control Unit ...........................85 Display and Programming Unit of Burner Control Unit ...86 Shutting Down the System ........................................87 Checking the 15A and 15B Flue Gas Sensor ................88 3A and 3B Boiler Temperature Sensor Description ....... 89 Boiler Flue Gas Temperature Sensor ............................90 Boiler Water Temperature Sensor ...............................91 Manual Reset Limits .................................................92 Gas Valve ...............................................................93 Air Pressure Switch ............................................... 93 Ignition Unit ............................................................95 Ignition Cables.........................................................95 Fan.........................................................................95 Rotary Damper and Servomotor .................................96 Checking and Cleaning the Burner Tube ......................97 Checking the Ignition Electrodes and Ionization Electrode ..98 Cleaning the Burners .............................................. 98 Cleaning the Combustion Chamber and Heating Surfaces .....................................................99 Checking all Connections Around the Heating Water for Leakage ........................................................... 100 Cleaning the Condensate Drainage System ................100 Further Assembly and Commissioning .......................101 Checking for Flue Gas Leakage .............................. 101 Automatic Leakage Test for Valves of the Combined Gas Valve ............................................................. 101 5776 774 - 05 Checking On-site Gas Connections for Leakage ..........102 Taking Final Measurement Reading ..........................102 Checking the Water Conditions...............................102 Checking Expansion Chamber and System Pressure ... 103 Mixing Valve Movement and Leak Check...................103 Checking Air Intake in the Installation Room (visual check) ........................................................ 104 Instructing the Operator of the System .....................104 Operating and Service Documents ............................ 104 5 Table of Contents Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Page Coding Levels Calling up Coding Levels ..................................... 105 Resetting Coding to their Factory Set Condition .........105 Coding Level 1 “General” Group..................................................... 106 “Combustion Controller” Group ................................ 108 “Boiler” Group ....................................................... 108 “Cascade” Group ..................................................109 “DHW” Group ........................................................ 111 “Solar” Group .................................................. 112 “Heating Circuit...” Group....................................... 113 Service Scans 6 “General” Group..................................................... 117 “Combustion Controller” Group ................................ 125 “Boiler” Group ....................................................... 126 “Cascade” Group ..................................................126 “DHW” Group ........................................................ 129 “Solar” Group .................................................. 131 “Heating Circuit...” Group....................................... 135 Calling up the Service Menu ...................................142 Leaving the Service Menu .......................................142 Change Passwords .................................................142 Resetting all Passwords to Factory Settings .............142 Scanning Operating Data ........................................ 142 Resetting Operating Data .......................................143 Breif Scan ............................................................. 143 Carrying Out an Actuator Test ................................ 144 Checking Sensors ................................................... 145 Maintenance Display ............................................... 145 Troubleshooting Fault Display.......................................................... 146 Boiler System Fault Codes ........................................ 147 Burner Fault Codes ................................................153 Burner Control Unit Burner Control Unit................................................156 Resetting Operating Parameters to Factory Settings ....160 Manual Mode and Service Display ............................ 160 Burner Control Unit Flow Diagram ............................ 161 Burner Control Unit Connection Diagram ...................163 Faults ................................................................... 164 Fault Codes ....................................................... 165 Faults Without Fault Display .................................... 168 Parts Parts Lists ............................................................. 170 Function Description Boiler Water Temperature Control ...........................181 Cascade Control Unit .............................................. 181 Heating Circuit Control Unit ..................................... 186 DHW Tank Temperature Control............................... 190 Sensors ................................................................ 194 Pressure Switches ................................................. 195 Burner Parts.........................................................196 Accessory Extension EA1 Accessory ......................................197 5776 774 - 05 Coding Level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Table of Contents Page Vitocom 100, LAN 1 Connection and Wiring Diagrams 5776 774 - 05 Additional Information Safety and Liability ............................................. 198 System Requirements ............................................. 199 Operation with Vitotrol App .................................. 200 Operation with Vitotrol 100 User Interface ................201 Checking Network Settings................................... 201 Sequence Overview ................................................ 202 Overview Of Connections ..................................... 202 Connecting to the Network (LAN)............................. 203 Display and Control Elements ................................ 203 Switching on the Vitocom 100 ................................ 205 Checking the LON Connection to the Vitotronic Control Unit....................................................... 206 Configuring Network Using Static IP .........................207 Registering the User Setting up the Heating System .. 208 Function Test ........................................................ 208 Enabling Maintenance .......................................... 209 Regular Function Testing ......................................... 209 Return to Factory Set Condition ............................. 209 Troubleshooting Measures ....................................... 210 Burner Control Unit Connection Diagram.................. 211 Boiler Connections.................................................. 212 Overview .......................................................... 213 PCB Extension for Heating Circuits 2 and 3 with Mixing Valve ......................................................... 214 PCB Low Voltage................................................ 214 PCB 120V~ .......................................................... 215 Requirements for Water Conditions........................... 216 Boiler Dimensions ............................................... 217 Technical Data ....................................................... 218 Maintenance Records .......................................... 220 Maintenance Schedule ............................................ 220 7 General Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Important Regulatory and Installation Requirements For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professional for the installation of hard-wired carbon monoxide detectors. a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (b) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 8 5776 774 - 05 2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. General Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Important Regulatory and Installation Requirements For Polypropylene venting systems only Minimum and maximum wall thickness through which the horizontal vent-air intake termination may be installed: Minimum: 1 in. (25.4 mm) Maximum: 30 in. (762 mm) Vent-air intake system must be properly installed and sealed. If PP(s) venting system passes through an unheated space, such as an attic, it must be insulated. The insulation must have an R value sufficient to prevent freezing of the condensate. Armaflex insulation with b in. thickness and higher can be used. Venting clearance to combustibles (Stainless Steel / Polypropylene) As per vent manufacturer’s requirements. WARNING Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury, or loss of life. Flue gases may contain deadly carbon monoxide. CAUTION Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (e.g. aluminum sheeting) may be required to prevent staining or deterioration. The protective material should be attached and sealed (if necessary) to the building before attaching the vent termination. It is strongly recommended to install the vent termination on the leeward side of the building. ASME CSD-1 Standard The ASME CSD-1 standard is published by ASME (American Society of Mechanical Engineers) and covers the requirements for the assembly, installation, maintenance, and operation of the controls and safety devices on automatically operated boilers directly fired with gas, oil, gas-oil, or electricity. The gas valve of this boiler meets the requirements as set forth in the ASME CSD-1 standard. 5776 774 - 05 IRI (Industrial Risk Insurers) IRI (Industrial Risk Insurers) requirements for boilers have been replaced by GE Global Asset Protection (GAP) Services requirements, please refer to section describing GE GAP requirements. (continued) FM (Factory Mutual) Global FM Global (formerly Factory Mutual Systems) participates on the ASME CSD-1 Committee and has aligned their requirements with those of ASME CSD-1. FM Gobal will accept a standard UL or ETL Listed Boiler complying with ASME CSD-1 up to 2,500,000 BTU. From 2.5 to 12.5 Million BTU, they still align with the ASME CSD-1 standard but may require additional FM Global approved components. Note: The local GE GAP or FM Global Inspectors have the right to request additional safeguards for unusual risks, but the ASME CSD-1 standard as outlined is normally accepted as meeting their requirements. Working on the equipment The installation, adjustment, service, and maintenance of this boiler must be performed by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water boilers. There are no user serviceable parts on the boiler, burners, or control. Note: The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. This includes low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc. Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work. Technical literature Literature for the Vitocrossal 300, CA3 boiler: - Technical Data Manual - Installation and Service Instructions - Operating Instruction - Instructions of other products utilized and installed - Installation codes mentioned in this manual and as locally applicable Note: Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact Viessmann for additional copies. This product comes with several safety instruction labels attached. Do not remove! Contact Viessmann immediately if replacement labels are required. GE GAP (Global Asset Protection) GE GAP Services publishes GE GAP Guidelines for various risks including boiler combustion codes and standards. In many cases, they adopt other existing nationally recognized standards. GE GAP Guidelines replace and eliminate the former IRI requirements. GE GAP requires compliance with ASME CSD-1 up to 12,500,000 BTU. 9 General Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service About these Installation Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below. WARNING Warnings draw your attention to the presence of potential hazards or important product information. Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage. CAUTION Cautions draw your attention to the presence of potential hazards or important product information. Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/ property damage. IMPORTANT Helpful hints for installation, operation or maintenance which pertain to the product. This symbol indicates that additional, pertinent information is to be found. This symbol indicates that other instructions must be referenced. Product Information High efficiency gas-fired hot water condensing boiler. For operation with modulating boiler water temperatures in closed loop, forced circulation hot water heating systems. The Vitocrossal 300, CA3 boilers are CSA certified with Viessmann burners which must be used in conjunction with this boiler series. The proper burner size must be verified and the burners are factory adjusted so that the maximum input of the appropriate boiler size is always observed. The gas burners must always be installed according to the instructions provided by the burner manufacturer. The Vitocrossal 300, CA3 boiler is suitable for a maximum operating pressure of 160 psig and a maximum boiler water temperature of 210°F (99°C). This boiler does not require a flow switch. WARNING Exposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void. 10 5776 774 - 05 The boiler model selected should be based on an accurate heat loss calculation of the building. The boiler selected must be compatible with the connected radiation. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Information Mechanical Room The Vitocrossal 300, CA3 boiler should be located in a heated indoor space. The boiler should also be located near a floor drain and as close as possible to the vertical chimney or vent. Whenever possible, install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area. Install boiler on flooring capable of supporting the weight of the boiler filled with water. Do not use exhaust fans without adding additional provisions for fresh combustion air (e.g. fresh air fan) in the boiler room and do not install the Vitocrossal 300, CA3 boiler in rooms with refrigeration equipment. This boiler requires uncontaminated air for safe operation do not install where chemicals are stored. Do not operate when air is polluted with halogenated hydrocarbons (e.g. as in aerosols, paints, solvents and cleaning agents) Prevent very dusty conditions Prevent high levels of humidity Prevent freezing and ensure good ventilation. Otherwise, the system may suffer faults and damage. For Retrofit Applications Before boiler is connected to piping/heating system, (which have been previously in service) the piping must be flushed with city pressure water (50-60 psi) to remove sludge and other contaminates. 5776 774 - 05 Failure to flush out the heating system piping may result in restricted flow and/or deposits resulting in boiler failure. This failure is not covered under warranty. 11 Boiler Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Recommended Minimum Service Clearances CA3 3.5 and 4.0 To enable convenient installation and maintenance, observe the stated clearance dimensions. Maintain the minimum clearances where space is tight. CA3 Model 4.0 5.0 6.0 a *1 in. (mm) 31b (800) 31b (800) 31b (800) 31b (800) b *2 in. (mm) 30 (760) 30 (760) 30 (760) 30 (760) in. (mm) 39e (1000) 39e (1000) 39e (1000) 39e (1000) 31b (800) 31b (800) 31b (800) 31b (800) c Top clearance CA3 5.0 and 6.0 3.5 Mechanical room Avoid air contamination by halogenated hydrocarbons (e.g. as in sprays, paints, solvents and cleaning agents) Avoid very dusty conditions Avoid high levels of humidity Protect against frost and ensure good ventilation, otherwise the system may suffer faults and damage. In rooms where air contamination from halogenated hydrocarbons is to be expected, operate the boiler using only direct vent (sealed combustion) operation only. Minimum clearances to combustibles CA3 Model 3.5 4.0 5.0 6.0 Top 0 Sides 0 Flue per vent manufacturer’s specifications Front 0 Floor combustible Legend A Boiler *2 12 Clearance may be reduced in multi-boiler installations, provided the side panel removal is not required and combustion air intake kit is not being used. Clearance for vent pipe installation. 5776 774 - 05 *1 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Unpacking and Placement of Boiler Unpacking boiler 1. Unscrew back panel. 2. The remaining packaging parts are screwed together. Open the packaging parts in the following order: Front panel Top panel Left side panel Right side panel Positioning boiler The boiler must be placed on a foundation. A minimum height of 4 in. (100 mm) is required in order to allow for the condensate siphon connection. 3. Raise boiler from the packaging platform with a lift truck or forklift. Lifting the boiler 1. There is a boiler lifting location for the forks of a lift truck or forklift on the right and left side of the boiler. 2. There is a boiler lifting location for the forks of a lift truck or forklift on the front of the boiler. IMPORTANT When lifting the boiler from the side ensure the forks of the lift truck or forklift are centered. Refer to the crosshair mark located on the side of the boiler. It is essential to use appropriate lifting devices certified of lifting to a minimum of the boiler weight. Boiler model a Boiler weight 3.5 4.0 5.0 6.0 in. (mm) 82f (2100) 82f (2100) 114d (2900) 114d (2900) lb. (kg) 4982 (2260) 5093 (2310) 6592 (2990) 7187 (3260) All CA3 boilers Total height (all CA3 boilers) Height not including upper panels, upper frame elements, burners and piping in. (mm) 84 (2136) 77c (1975) WARNING If flue gas connection is damaged leakage may occur. Do not lift boiler at the flue gas connection. Reducing Boiler Height Reducing the overall height of the boiler during placement The overall boiler height can be reduced for placement. Panels, frame elements with piping and burners can be dismantled for this purpose. Additional height reduction is achieved by dismantling of the control unit (Control cabinet). Dismantle the upper panels and upper frame elements with piping and burners 1. Dismantle panels. Top panels Upper side panels Upper rear panel 4. Remove burners. See page 82. 1. Release gas connection. 2. Disconnect electrical connections. 3. Dismantle electrodes. 4. Disconnect upper burner section and extract with lifting mechanism. Note: A lifting mechanism that can be mounted to the boiler frame is available as an accessory. 5. Dismantle upper frame profiles. Dismantling the control cabinet 1. Dismantle cover plates and doors of control cabinet. Note: Once the boiler is into position, reassemble removed components in reverse order. 2. Dismantle boiler supply header. 5776 774 - 05 3. Dismantle upper frame profile. 13 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Preparing the Boiler Note: It is recommended that the levelling bolts included with the boiler are used when installing the boiler on uneven surfaces. 1. Once removed from the wooden shipping pallet from the boiler base. Remove the 4 leveling bolts A from boiler’s accessory package and install into the four corners of the boiler base. 2. It is recommended to place a flat piece of steel plate under each leveling bolt for better weight distribution and adjustment. 3. Level the boiler, by adjusting the floor levelling bolts. Water Side Connection Note: Make all connections free of load and torque stresses. The heating system must be properly flushed, especially if the Vitocrossal 300, CA3 boiler is connected to an existing heating system in a retrofit application. See page 11 for details. Connect the system to the boiler according the diagram on page 42. Note: All connections which are not being utilized for water connections or for controls must be properly closed. The supplied air vent and pressure relief valve must be installed on the supply header of the boiler - the alternate pressure relief valve location may be in the boiler supply line. The piping to the precharged expansion tank, as well as any automatic feed water required, must be connected to the boiler return. Boiler pump shall be installed on return pipe, pumping water into the boiler. The supplied low water cut-off should be installed directly on the safety header of the boiler or may be installed in the boiler piping above the pressure vessel. Note: Piping diagrams for specific system layouts are available. Please enquire with your local Viessmann sales representative. The Vitocrossal 300, CA3 boiler is only suited for hot water heating. Do not install a 4-way mixing valve, bypass valve or similar. 14 5776 774 - 05 IMPORTANT Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service 5776 774 - 05 Boiler Connections Legend 1 Boiler return: (ANSI 4 in. for models 3.5, 4.0 and 5.0 and ANSI 6 in. for model 6.0) *1 2 Boiler supply: (ANSI 4 in. for models 3.5, 4.0 and 5.0 and ANSI 6 in. for model 6.0) *1 3 Safety header: (Pressure relief valve, low water cutoff, automatic air vent and temperature/ pressure gauge) A Hex bushing b in. x e in. B Air vent with shut-off base C Plug b in. D Reducer 2 in. to 1a in. for models 3.5 and 4.0, 2 in. to 1b in. for models 5.0 and 6.0 E Nipple - 1a in. for models 3.5 and 4.0 - 1b in. for models 5.0 and 6.0 F Pressure relief valve, 75 psi *2 G Low water cutoff H Temperature/pressure gauge 4 Drains: I Nipple 1a in. x 10 in. J Reducer 1a in. x c in. K Sediment faucet c in. 5 Gas line fittings: L Gas ball valve, 2b in. for models 3.5 and 4.0, 3 in. for models 5.0 and 6.0 Safety Header CAUTION Do not connect heating system to safety header. 1. Locate safety header on the main supply header. Water pressure: 160 psi (11 bar) Testing pressure: 240 psi (16.5 bar) Min. water pressure: 8 psi (0.5 bar) Note: The minimum water pressure is necessary for safe operation. Note: All boilers must have a pressure relief valve. Note: Make all connections free of load and torque stresses. *1 Counter flanges, gaskets and hardware (field supplied) *2 Alternate pressure relief valves are available depending on operating pressure requirements. Contact your local Viessmann sales representative for details. 15 Installation Boiler Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Hydrostatic test procedure All Vitocrossal 300, CA3 boilers are factory tested (hydrostatic testing) to ASME requirements. The following testing procedure is to ensure that the boiler remained intact during shipping and handling. 1. Isolate boiler from hydronic heating system using isolating valves (i.e. expansion tank, feed water valve, pressure relief valve etc.). 2. Remove 75 psig pressure relief valve from the boiler and cap pipe outlet. 3. Fill boiler with city water and pressurize it to one and a half (1½) times the maximum working pressure of boiler. The pressure must be controlled such that it will never be 10 psig higher than the testing pressure. Max. allowable working pressure: 160 psig Testing pressure: 240 psig (do not exceed 250 psig) WARNING Never expose the boiler to any pressures higher than 250 psig during testing. Legend A Boiler supply B Temperature/pressure gauge C Pressure relief valve D Boiler return E Drain valve F Precharged expansion tank G Automatic fill H Condensing water drain I Flue gas test port 4. Monitor pressure over a period of approximately one hour to ensure that the pressure remains constant and steady at 240 psig. 5. Should there be a drop in pressure, ensure that all fittings are secure and tight. Check all flanged connections with a flashlight. 6. Open the boiler combustion chamber and inspect with a flashlight the front portion of the Inox-Lamellar heat exchanger sections for system water or fluid. 7. If test is successful, reinstall all hydronic system components and refill the boiler with water or system fluid. WARNING 16 5776 774 - 05 Fill only suitable water in boiler (refer to Service instructions). Unsuitable water quality may damage boiler. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler Connections Installation (continued) Boiler water drain valve Using a water drain valve facilitates the drainage of a heat exchanger. The supplied drain valve must be installed in each boiler section before filling. 1. Locate and remove drain plug for each boiler section. 2. Install drain valve assembly for each boiler section as shown. Legend A 1a” x 10” nipple B 1a” to c” reducer C c” sediment faucet 5776 774 - 05 Installing the isolation valve handle Remove the isolation valve handle A from the accessory pack and insert it into the receiver handle B of the isolation valve until it locks into place. Repeat for all valves. Note: The handle is only used for initial installation and for service. The handle must be removed prior to putting the boiler into operation. 17 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Cable routing on boiler The cable trays are on the left side of the boiler. IMPORTANT Route power supply cables and low voltage cables separately using the cable trays provided. 1. Lift and remove left lower side panels. 2. Lift and remove upper front panel. 3. Using supplied ‘panel key’, unlock the front panel and swing door open. Legend A Upper cable tray for power supply cables (e.g. boiler power supply) B Lower cable tray for low voltage cables (e.g. sensor cables) 18 5776 774 - 05 4. Remove upper and lower mid panels for the Vitotronic 300 GW6C control. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Installation (continued) 5776 774 - 05 Connections overview Legend A Supply temperature sensors heating circuits M2/M3 B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connections D Boiler power supply connection E Pumps/mixing valve connections F Internal disconnect switch (with lockout provision) 19 Installation Electrical Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Heating circuit - extension connection Legend ? M2/M3 supply temperature sensor Low voltage connections at the system and boiler section 1 controller Outdoor temperature sensor Fitting location for outdoor temperature sensor H North or north-westerly wall, 6 to 8 ft (2 to 2.5 m) above ground level; in multi storey buildings, in the upper half of the second floor. H Not above windows, doors or ventilation outlets. H Not immediately below balconies or gutters. H Never paint over. ! Outdoor temperature sensor §/? Common supply temperature sensor %A Tank temperature sensor %B Tank temperature sensor (bottom) in a tank loading system (accessory) aJB Tank temperature sensor tank loading system (accessory) aVD External connection aVG KM-BUS i.e. Extension EA1 (accessories) aVH External connection FA Burner control unit connected 20 Outdoor temperature sensor connection 2 wire cable, 18 AWG for a maximum length of 115 ft. (35 m). 5776 774 - 05 Extra-low voltage printed circuit board connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Installation (continued) Note: The DIN terminals can be used with solid, stranded or stranded with ferrule termination. The ferrule will help to prevent ‘fraying’ of the stranded wires during installation. Specific connections are detailed throughout the manual, refer to the appropriate section prior to making any connections. Accessory connections The accessory terminals include a L, N terminal connection orientated at the top of the rail which is prewired to the cable harness set. The L, N, G terminals orientated at the bottom of the DIN rail for accessory connection is used to for connections to external equipment (ie. Pumps, mixing valves, etc). The individual terminals are a ‘push-in’ design, meaning to install or release a wire, the orange button must be pushed in (refer to image below for location of orange buttons denoted by B), prior to installing or removing any wires to the terminal. Top 5776 774 - 05 Bottom Legend A DIN terminal accessory connections B Push-in button C DIN rail (typical) D Terminal insertion point 21 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Top (continued) Main power supply connections The main power supply terminals are a push-in design. To install or release a wire from the terminal push the orange button B. The main power supply terminal will accept only one connection L, N or G. Each terminal is designated by color: Grey - Line Blue - Neutral Green / Yellow - Ground Refer to page 30 for power supply connection details. Bottom Internal control fuse F3 When fuse F3 requires replacement, (refer to the separate wiring diagram) the fuse can be accessed as shown. 1. Flip down the front portion of the DIN rail mounted fuse block. 22 3. Replace fuse. 4. Return the DIN rail mounted fuse block back to the original position. 5776 774 - 05 Legend B Push-in button C DIN rail (typical) D Terminal insertion point 2. Flip down the front side cover of the DIN rail mounted fuse block. Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections (continued) Connecting Pumps Available connections Rated voltage 120V~ Rated current Max. 2A~ Note: Maximum output 6FLA shared between all 120V outputs. Pumps 120V Available pump connections 5776 774 - 05 sÖA1 sÖM2 sÖM3 sA sK sL Heating circuit 1 pump Heating circuit 2 pump Heating circuit 3 pump DHW pump DHW recirculation pump Boiler pump/common supply pump Connections on extension for heating circuit with mixing valve HC2/M2, HC3/M3 Plug Terminal Component 5 L, N, G Heating circuit pump sÖ M2 6 L, N, G Heating circuit pump sÖ M3 Connections on the PCB 120V~ 9 L, N, G sÖA1 sK 8 7 sL 10 L, N, G sA L, N, G L, N, G Heating circuit pump for heating circuit A1 or Primary pump, tank loading system DHW pump DHW recirculation pump boiler pump, system pump 23 Installation Electrical Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Connecting Pumps (continued) 120V pumps with an amperage draw of <2FLA A DIN rail (located in the junction box) B Pump 24 5776 774 - 05 120V pumps with an amperage draw of >2FLA Contactor specification 120VAC 1A A DIN rail (located in the junction box) B Contactor/relay (field supplied) C Pump D Power supply w/disconnect and protection Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Installation (continued) Connecting Pumps (continued) 240V pumps Contactor specification 120VAC 1A A DIN rail (located in the junction box) B Contactor/relay (field supplied) C Pump D Power supply w/disconnect and protection 5776 774 - 05 208/460/575V 3 phase pumps Contactor specification 120VAC 1A A DIN rail (located in the junction box) B Contactor/relay (field supplied) C Pump D Power supply w/disconnect and protection 25 Installation Electrical Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Connecting a Central Fault Message Facility Plug gÖ (terminal 11 - L, N, G) Rated voltage 120V~ Rated current Max. 2A~ Note: Maximum output 6 FLA shared between all 120V outputs. Connecting Actuators 1. Disconnect power to control. 2. Connect valve actuator wires to the DIN terminals as shown (based on desired functionality). Available connections gSM2 For heating circuit 2 gSM3 For heating circuit 3 Rated voltage 120V~ Rated current Max. 0.1A~/ output Motor runtime for 3-way mixing valve: 10 to 255 sec, adjustable via coding addresses “c3” in the heating circuit 2 group and “c3” in the heating circuit 3 group. Plug DIN terminals 52M2 1 (L, N) 2 (L) 52M3 3 (L, N) 4 (L) 26 5776 774 - 05 Legend A DIN Rail (in junction box) B 120V Valve Actuator C Valve Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections (continued) Connecting Actuators (continued) Legend A 24V Mixing Valve Adaptor B DIN Rail (in junction box) C 24V Valve Actuator D Valve E 120V power to the mixing valve adaptor 24V Valve Adaptor Rated voltage: Rated current: 24VAC max. 0.15 FLA Available connections gS M2 For heating circuit 2 gS M3 For heating circuit 3 Motor runtime for 3-way mixing valve: 10 to 255 sec, adjustable via coding addresses “c3” in the heating circuit 2 group and “c3” in the heating circuit 3 group. 1. Disconnect power to control. 2. Remove plug connect gS from cables BK1, BK2 and BK3 of the 24V valve adaptor. 3. Connect BK1, BK2 and BK3 to DIN terminals for desired valve application. Refer to the chart below. 4. Connect black wire E of the mixing valve adaptor to an available terminal 12-14 on the DIN rail. 5. Connect valve actuator wires to the adaptor terminals as shown in image above. Refer to the mixing valve adaptor Installation Instructions for additional information. Plug gSM2 DIN terminals 1 (L, N) 2 (L) gSM3 3 (L, N) 5776 774 - 05 4 (L) 27 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections (continued) Connection of Low Water Cut-off Device * * 1. Remove jumper between terminals 15(L) and 16(L). 2. Make connection for (LWCO) switching contact at terminals 15(L) and 16(L). 3. Power supply for low water cut-off device made at an available (L, N, G), terminals 12, 13 or 14. CAUTION The diagram shown is only a simplified conceptual drawing of a typical low water cut off (LWCO) device. Refer to the manual specific to the device for interconnection details. *Factory Installed high limit temperature switches (refer to page 92 for additional information). A 28 5776 774 - 05 Legend A Low water cut-off (typical) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections Installation (continued) Connecting External Safety Equipment * * Connection at plug aBÖ. Note: ‘Live’ contacts lead to short circuits or phase failure. The external connection must be potential-free. 1. Remove jumper from terminals 17(L) and 18(L), 19(L) and 20(L) or 21(L) and 22(L). 2. Make connection of the safety equipment to 17(L) and 18(L), 19(L) and 20(L) or 21(L) and 22(L). *Factory Installed high limit temperature switches (refer to page 92 for additional information). Legend A Minimum pressure limiter B Maximum pressure limiter C Further safety equipment 5776 774 - 05 Note: Periphery equipment attached to the aBÖ plug must be operated on a normally closed circuit. 29 Installation Electrical Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Power supply connection CA3 3.5 and 4.0 120 VAC/60 Hz/1 phase (20 Amp) Power supply connection CA3 5.0 and 6.0 208 Y/120VAC-60Hz - 3 phase (20 Amp) (4 wire L1, L2, L3, N, G) Power supply connection CA3 3.5 and 4.0 WARNING The control must be grounded. Ensure that ‘L’, ‘N’ and ‘G’ are not interchanged. WARNING Incorrectly executed electrical installations can lead to injuries from electrical current and result in appliance damage. 240 VAC/60 Hz/1 phase (20 Amp) (optional power supply) 30 5776 774 - 05 Legend 1 Factory installed terminal bridge 2 Terminal bridge must be removed on site for 240VAC connection. Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections EA1 extension (continued) External block via output contact Connection options: Extension EA1 (accessories, see page 197). Contact closed: Controlled shutdown of burner of each boiler section. Any connected boiler circuit pump or distributor pump will be switched off. Shut-off devices are closed. IMPORTANT There is no frost protection for the heating system during the block. Legend A Potential-free dry contact B EA1 Extension Connection CAUTION The external connection must be potential-free. Coding EA1 extension Set “5D“ (DE1), “5E“ (DE2) or “5F“ (DE3) in the “General” group to 3 or 4. External Demand via 0 –10V Input Connection at input 0 – 10V to EA1 extension (accessory, see page 197). Note: Ensure DC separation between the ground conductor and the negative pole of the on-site voltage source. 0 –1V 1V 10V Observe No default set supply temperature Set value 50°F (10°C) Set value 212°F (100°C) coding “1E” in the “General” group. 5776 774 - 05 Optional setting range 0 –1V No default set supply temperature 1V Set value 86°F (30°C) Set value 248°F (120°C) 10V Observe coding “1E” in the “General” group. 31 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Electrical Connections (continued) External Operating Program - Changeover Connection options: EA1 extension (accessories, see page 197) Connection CAUTION The external connection must be potential-free. EA1 Extension The changeover for heating circuits 1 to 3 can be implemented separately. Legend A Potential-free contact B EA1 extension Preselected operating program (Contact open) Coding Changed over operating program (Contact closed) 9 Central heating off/DHW heating off “d5:0“ in the “Heating circuit...“ Constant operation with group (factory set condition) reduced room temperature/ DHW heating off. w Central heating off/DHW heating on rw Central heating on/DHW heating on “d5:1“ in the “Heating circuit...” Constant operation with group standard room temperature, coding as per DHW heating “64“ in the “DHW“ group. or or Coding EA1 extension Set “5D“ (DE1), “5E“ (DE2) or “5F“ (DE3) in the “General” group to 1. The function can be assigned to the heating circuits at coding “d8” in the “Heating circuit...” group. Making the LON Connection Establishing a LON-Connection The Viessmann LON is designed for the BUStopology “line” with double-sided terminating resistors (Accessories). For further information please see “Viessmann LON-Handbuch“ at www.viessmann.de/lon. The transfer distances for LON are dependent upon the electrical characteristics of the cable. For this reason only the specified cable types may be used. Only one type of cable may be used within a LON. Types of cable (on-site): 2-core cable, CAT5, screened JY(St)Y 2 x 2 x 0.8 mm (Telephone cable) 32 5776 774 - 05 The requirements for cables and operation of the LON interface FTT 10-A must be observed (see www.echelon.com). All Viessmann equipment is connected via RJ45 plugs. Cores “1” and “2” and screening are required for the Viessmann LON. The cores are interchangeable. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Making the LON Connection (continued) Connection with Viessmann LON cable Installation distance Installation ≤ 23 ft. (7 m) long. Legend Vitocrossal 300 CA3 control unit (Vitotronic 300 GW6C) B LON connecting cable, 23 ft. (7 m) long C Terminal end resistor LON External LON participants A Connection with Viessmann LON cable and coupling Installation clearance 23 to 69 ft. (7 to 21 m). Connection with on-site cable and LON plug Installation distance ≤ 3000 ft. (900 m) (with LON plug). Legend A Vitocrossal 300 CA3 control unit (Vitotronic 300 GW6C) B On-site cable C Terminating resistor D LON plug F Up to 30 participants LON External LON participants Connection with LON cable, on-site cable and LON junction box Installation distance ≤ 3000 ft. (900 m) (with LON junction box). 5776 774 - 05 Legend A Vitocrossal 300 CA3 Control unit (Vitotronic 300 GW6C) B LON connecting cable, 23 ft. (7 m) long, max. 3 cables between 2 appliances C Terminal end resistor D LON coupling LON External LON participants Legend A Vitocrossal 300 CA3 control unit B LON connecting cable, 23 ft. (7 m) long C Terminal end resistor D LON Connecting plug E On-site cable F Up to 30 participants LON External LON participants 33 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Connecting Flue Gas Pipe IMPORTANT Connect flue gas collector with the flue gas pipe using the shortest possible route. Avoid sharp bends. Nominal diameter boiler-flue gas pipe CA3 Model in. (mm) 3.5 4.0 12” (306.8 mm) 5.0 6.0 16” (408.4 mm) 1. Fully insert flue gas adapter inside the flue outlet (if used with stainless steel piping). IMPORTANT Ensure that the venting system is fully inserted into the flue gas collector. Once installed, verify that the vent and the vent pipe coupling connections are free of leaks by using a certified leak detector. Note: Connect the flue outlet with the flue pipe via the shortest possible run, with slight rise (min 3°). Avoid sharp bends. 2. Connect flue system. Size: 12 in. (300 mm) for boiler 3.5 and 4.0, 16 in. (400 mm) for boiler 5.0 and 6.0. Note: Support all venting components; make all connections free of load and torque stresses. The venting system must be securely supported by an anchoring system as outlined by the venting manufacturer. IMPORTANT The boiler flue gas collector vent is not designed to support the weight of the venting system. 34 5776 774 - 05 Legend A Flue vent collar coupling (supplied with boiler) Note: The flue gas collector outlet is designed to accept most vent manufactures venting systems directly (refer to the dimensions above). A flue gas adaptor may be required and is not included with the boiler. If required the adaptor must be supplied by the venting manufacturer. Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Connecting Neutralization System IMPORTANT The neutralization system is available as an accessory. Refer to the Installation and Operating Instructions for the neutralization system. 1. Mount neutralization system A behind or next to the boiler. 2. Install syphon C (included with boiler) and fill with water. Legend A Neutralization system B Hose (supplied with neutralization kit) C Boiler siphon D Hose (supplied with neutralization kit) E On site drainage system F Flue gas collector 3. Shorten supplied plastic hose B to the required length. Connect to syphon and neutralization system. 4. Connect drain hose D to the condensate drain of the neutralization system and install at drainage E. IMPORTANT Drainage must be lower than the siphon. WARNING 5776 774 - 05 Escaping flue gas can cause severe personal injury or loss of life. Always connect the condensate drain with a syphon in order to prevent flue gas from escaping. 35 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Condensate Connection The Vitocrossal 300, CA3 boiler is supplied with a condensate trap (field installed). An external trap is not required when connecting the field drain to the P-trap. Discharge tubing (field supplied) must be 1 in. diameter. Use CPVC, PVC or other material approved by code listed below. The drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada use CSA or ULC listed schedule 40 CPVC or PVC drain pipe, fittings and cement. 1. Install the condensate drain pipe with a suitable gradient. 2. Discharge condensate from the boiler into the drain system, either directly or (if required) via a neutralization unit (accessory). Legend A Condensate drain (must be able to be inspected) B Open or vented field supplied drainage system IMPORTANT Note: If the boiler is installed even with the ground, install a condensing drain above the ground max. 2 in. (50 mm). Do not connect the drain pipe from any other appliance, such as a water softener backwash pipe, to the Vitocrossal 300, CA3 condensate drain pipe. Boiler water return temperature Note: The ‘amount of condensate” and the “flue gas temperature gross” graphs are independent of each other. 36 Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable). IMPORTANT Always connect the drain with a P-trap or siphon to prevent flue gas from escaping into the space. Connection (external): 7 c in. (19 mm) barb fitting. The amount of condensate to be expected during the operation of the boiler and can be read from the chart. If the condensate outlet of the Vitocrossal 300, CA3 boiler is lower than the drain, a condensate pump must be installed. Select a pump which is approved for condensing boiler applications. To avoid condensate spillage, select a pump with an overflow switch. The drain connection must terminate into an open or vented drain as close to the boiler as possible to prevent siphoning of the boiler drain. 5776 774 - 05 Flue gas temperature gross . emp as t put g e n Flu full i at . emp as t load g e Flu artial at p of nt e ou sat Amnden co Amount of condensate IMPORTANT Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Installation Gas Connections Legend A Gas shut-off valve B Low gas pressure switch C High gas pressure switch D Fan pressure switch E Test fire valve F Venturi Honeywell combination gas valve assembly model V4734C1010-1100-1 Legend 1 Burner section 1, lead 2 Burner section 2, lag 1 3 Burner section 3, lag 2 (applies for Vitocrossal 300, CA3 models 5.0 and 6.0) Note: Each burner control requires a manual reset of low gas pressure conditions. Honeywell combination gas valve assembly model V4734C1010-1100-1 5776 774 - 05 Honeywell combination gas valve assembly model V4734C1010-1100-1 Additional components may be required as specified by: 248-CMR-7:00, N.B.C., NFPA 54 and/or ANSI Z223.1 Legend A Field supplied and installed gas shut-off valve B Field supplied and installed union C Field supplied and installed service gas pressure regulator (required for all installations) D Field supplied and installed union E Gas shut-off valve F Built-in low gas pressure switch G Gas pressure regulator H High gas pressure switch I Test firing valve J Direct spark ignition burner with venturi K Fan pressure switch to low fire gas pressure regulator 1* 7 1a in. for individual burner sections 2* 7 2b in. for Vitocrossal 300, CA3 models 3.5 and 4.0 7 3 in. for Vitocrossal 300, CA3 models 5.0 and 6.0 37 Installation Gas Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) The gas line on the burner meets the requirements of ASME/CSD-1. 1. Connect gas pipe A to the gas valve. Gas connection: Vitocrossal 300, CA3: 2b in. NPT for models 3.5 and 4.0, 3 in. NPT for models 5.0 and 6.0. 2. Test leak tightness of gas pipe connection using an approved method. 3. Purge gas line in a safe manner using an approved purge burner. WARNING If test pressure is too high burner and gas fittings may get damaged. WARNING Escaped gas may lead to explosion, which could cause severe injuries. Do not vent gas pipe above combustion chamber of boiler. CAUTION 38 5776 774 - 05 If gas pipe contains dirt it is recommended to install a gas filter into the gas pipe. Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Gas Connections (continued) 1. Refer to current CAN/CSA B149.1 and .2 or National Fuel Gas Code ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing. Pipe size to the boiler must be determined based on: - pipe length - number of fittings - type of gas - maximum input requirements of all gas appliances in the residence. IMPORTANT Design piping layout in such a way that piping does not interfere with serviceable components. 2. Before connecting boiler to gas line, install ground joint union, capped drip leg and a manual equipment shutoff valve. Valves must be listed by a nationally recognized testing agency. Make boiler gas connection as shown. 3. Perform gas piping pressure test as described in the following subsection. IMPORTANT Legend A Manual gas shutoff valve (supplied) B Nipple (field supplied) C Ground joint union (recommended) (field supplied) D Elbow (field supplied) E Cap (field supplied) F On site gas line Note: Illustration shown is a generic gas piping configuration, which may vary depending on specific system layout/requirements. WARNING Escaped gas may lead to an explosion, which could cause severe injuries or property damage. Note: Drip pocket shall be installed accordingly to CAN/CSA B149.1 or National Fuel Code ANSI Z223.1 / NFPA 54. Max. gas supply pressure: 14 “w.c. 4. Identify shutoff valves as such with a tab and familiarize operator/ultimate owner of boiler with these valves. Valve leak test This is a test for checking the leakness tightness of the valve and flange connections. It is recommended that this test be included in the scheduled inspection and maintenance procedures. IMPORTANT This test should only be performed by a trained licensed heating contractor. 1. Open the manual gas shutoff valve A. 2. Leak test all connections with a certified leak detector. 3. Close the manual gas shutoff valve A. 5776 774 - 05 4. Repair any leaks if necessary. 39 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Initial System Fill Treatment of boiler feed water should be considered in areas of known problems, such as high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system (maximum mix ratio - 50% / 50%). Please adhere to the specifications given by the antifreeze manufacturer for hydronic heating systems. IMPORTANT Only use antifreeze specific for hydronic heating systems. Do not use automotive glycol! Please observe that an antifreeze/water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks, radiation etc. A 40% antifreeze content will provide freeze-up protection to -31°F (-25°C). The heating system may also contain components which may be negatively affected by antifreeze. Check entire system frequently when filled with antifreeze. Read boiler service instructions for further information on water quality. CAUTION Before the heating boiler is installed and piped into an existing system, the heating system itself must be properly flushed to remove dirt and system sludge. Accumulations in old heating systems will tend to settle in the boiler and can lead to deposits which can cause hot spots, noise and water-side corrosion. For damages resulting from those kinds of impurities, the warranty will be null and void. The Vitocrossal 300, CA3 boiler is only suitable for closed hot water heating systems with pumps. It is strongly recommended to install boiler isolation valves and above these isolation valves, drain valves in the system supply and return. With this installed, any maintenance work on the boiler or heating system, will not require draining the entire system. The pressure relief valve must be attached to the top of the boiler or the safety supply of the boiler (see page 15). No valve, shut-off device or obstruction of any kind and no construction must be used between boiler and relief valve or on the discharge side of the pressure relief valve. The discharge side of the pressure relief valve must continue in the same size as the outlet horizontally over the side of the boiler, and then vertically downwards to end approximately 1 ft. (300 mm) above the floor, and piped as close to a floor drain as possible. Do not install this discharge pipe to the outdoors or any area where freezing might occur or the discharge pipe could endanger life and equipment. IMPORTANT Secure the discharge piping from the pressure relief valve with the appropriate hangers or brackets. IMPORTANT Cold water fill pressure must equal expansion tank pressure. The boiler should be filled and properly bled of air and the cold water fill pressure should not exceed 18-20 psig. All openings, as well as pipe connections on the boiler, should be observed for possible leaks. Once all connections are tight, the insulation can be mounted. IMPORTANT Ensure that there is no leak on any of the connections which are covered by the insulation. WARNING Fill only suitable water in boiler (refer to Service Instruction). Unsuitable water quality may damage boiler. When the boiler is utilized to supply heat to an indirectly heated domestic hot water tank, it is necessary that the heating loops (without a mixing valve) are equipped with flow check valves on the discharge side of the pumps to avoid reverse flow. IMPORTANT 40 5776 774 - 05 All system pumps must be installed from boiler supply to the system. Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local Viessmann sales representative office. Clearances A minimum of 2 in. (51 mm) circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained. In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0 in. (refer to local gas codes). CAUTION For underfloor heating applications, an additional immersion or strap-on aquastat must be installed in the low temperature underfloor loop (downstream of the mixing valve) to de-energize the pump and/or boiler to prevent overheating. High water temperatures can damage concrete slabs. IMPORTANT The examples on the following pages depict possible piping layouts of the Vitocrossal 300, CA3 boiler equipped with Viessmann System Technology. For boiler and tank combinations, please install only feasible combinations listed in the Viessmann Price List. WARNING If a DHW storage tank other than a Viessmann Vitocell 100 or 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank. Viessmann strongly recommends the installation of a temperature tempering valve in the DHW supply line. IMPORTANT DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections, shall be a minimum of 1¼ in. pipe size. This will ensure the residual head of the field supplied pump is fully utilized to overcome the resistance of the DHW heat exchanger coil and to provide sufficient water flow to the boiler heat exchanger. In non-Viessmann DHW tank applications, perform, in addition to the above, accurate calculations for DHW tank coil pressure drop versus boiler pump (field supplied) residual head to ensure sufficient water flow to the boiler heat exchanger. Failure to heed the above instructions may cause boiler short-cycling and inadequate DHW supply. Note: In the following piping layout examples all pumps are field supplied. 5776 774 - 05 Please note that the following examples are simplified conceptual drawings only! Piping and necessary componentry must be field verified. A low water cut-off (LWCO) must be installed where required by local codes. Proper installation and functionality in the field is the responsibility of the heating contractor. 41 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service System Layout 1 Vitocrossal 300, CA3 with... - DHW storage tank - one heating circuit without mixing valve - two heating circuits with a mixing valve 42 Installation of different heating circuits... ■ high-temp. circuit (radiator heating circuit) ■ low-temp. circuit (under floor heating circuit with 3-way mixing valve) ■ DHW production The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is controlled by an accessory kit for a heating circuit with mixing valve. IMPORTANT System separation is required of underfloor heating systems employing non-oxygen diffusion barrier tubing. All components on the secondary side of the heat exchanger must be made of corrosion-resistant materials. 5776 774 - 05 Legend A Vitocrossal 300, CA3 boiler B Outdoor temperature sensor ! C Low temperature heating circuit D High temperature heating circuit E Heating circuit pump F Mixing valve temperature sensor ? G Mixing valve with actuator H Domestic hot water storage tank I DHW tank temperature sensor % J Expansion tank K Boiler pump/system pump sL * L DHW pump sA M Low loss header N System supply temperature sensor ) * When using single speed boiler/system pumps, a hydronic pressure bypass may be required. O Hydronic pressure bypass (if required) Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service System Layout 2 Multiple (up to eight) Vitocrossal 300, CA3 with... - multiple heating circuits with mixing valves - low-loss header Legend A Vitocrossal 300, CA3 boiler B Low-loss header/common supply temperature sensor C Low-loss header D DHW storage tank E High temperature heating circuit F Low temperature heating circuit G Hydronic pressure bypass (if required) H Connection to BMS (BACnet/MODbus) I Heating system J Variable speed pump control (field supplied) * Optional accessory (depending on system layout and configuration) Note: When using single speed boiler/system pumps, a hydronic pressure bypass may be required. When designing a multiple Vitocrossal 300, CA3 system as shown above, please reference applicable multiple Vitocrossal 300, CA3 technical documentation, and contact your local Viessmann Sales Representative for further assistance. This installation example depicts a possible piping layout for multiple Vitocrossal 300, CA3 boilers equipped with Viessmann System Technology. Please note that this example is based on a simplified conceptual drawing only! Piping and necessary componentry must be field verified. A low water cut-off (LWCO) must be installed where required by local codes. Proper installation and functionality in the field is the responsibility of the heating contractor. 5776 774 - 05 WARNING If a DHW storage tank other than a Viessmann Vitocell 100 or 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank. Viessmann strongly recommends the installation of a temperature tempering valve in the DHW supply line. 43 Installation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler Piping in Heating/Cooling Application Heating / Cooling unit Heating / Cooling unit Heating / Cooling unit Water Chiller The Vitocrossal 300, CA3 boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel to the boiler and with appropriate valves to prevent the chilled medium from entering the boiler. The boiler piping system of a hot water heating boiler is connected to the heating coils located in the air handling units. The boiler piping system may be exposed to refrigerated air circulation and must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. Check the installation instructions of the chiller manufacturer carefully for additional requirements. 44 Cooling season starts: Close valve V1 and open valve V2. Heating season starts: Close valve V2 and open valve V1. Metal tags labelling these valves should be attached. IMPORTANT In the above system, the circulating pump must be operated from a separate on/off switch - not from the boiler control. 5776 774 - 05 Legend A System supply B System return C Valve D Flow check valve E Circulation pump F Automatic feed valve G Pre-charged expansion tank Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Venting Information Installation steps (outline) WARNING Ensure that the entire venting system is protected from physical damages. A damaged venting system may cause unsafe conditions. WARNING The venting system is approved for indoor installations only. Do not install the venting system outdoors. IMPORTANT Boiler operation in marine environments (damp, salty coastal areas): The service life of the Vitocrossal 300, CA3 boiler’s exposed metallic surfaces, such as the casing and fan housing, is directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray, coupled with relative humidity, can lead to degradation of the exposed metallic surfaces mentioned above. Therefore, it is imperative that boilers installed in such environments not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air dependent vent systems; i.e. using room air for combustion. The indoor air will have a much lower relative humidity and hence, the corrosion will be minimized. Route vent pipe as directly as possible and with as few bends as possible to the boiler. Check proper location of gaskets in rigid PP(s) pipe collars. (Only use supplied parts with the polypropylene venting system.) Apply water to lubricate the joint ends of the vent pipe collar and if used, the air intake pipe collar. Slide pipes into each other with a gentle twisting motion. Condensate must drain from the flue pipe to the boiler. Ensure a suitable gradient of at least 3º [approx. 2 in. per 3.3 ft. (50 mm per 1 m)]. Use a hacksaw or sheet metal snips (for stainless steel) to cut pipes to length (if necessary). Use a file to smooth rough edges. Pipe must be round and not bent into an oval shape. IMPORTANT When cutting pipes to length, deburr and clean pipes. For stainless steel and PP(s) venting systems: In conjunction with these instructions, follow the installation instructions supplied by the special venting manufacturer. If using room air-independent venting system, connect the air intake pipe (from outdoors) to the combustion air intake kit. If room air-dependent venting system is used, the air is drawn into the burner inlet through the screens on the right side of the boiler. Recommended venting practice When installing a venting system the following recommended venting practices apply: Keep length and number of 90º elbows to a minimum. Try not to use back-to-back 90º elbows. Use 45º elbows where possible to minimize the number of 90º elbows in case redirection of flue gas is required. The special vent system shall not be routed into, through, or within any other vent such as an existing masonry or factory-built chimney. Exception: A masonry chimney flue may be used to route the venting system only if no other appliance is vented in the same flue. Connecting Combustion Air Intake for Direct Vent Room air independent operation 5776 774 - 05 The connection set for the combustion air intake kit is available as an accessory. Refer to the installation instructions “combustion air intake kit”. 45 Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Venting Information (continued) Approved venting materials Part Material Certified to Standards Applicability Exhaust pipe and fittings Stainless steel UL1738 “Venting systems for gas-burning appliances, Categories II, III, IV” U.S.A./Canada ULC S636 “Standard for Type BH gas venting systems” PP(s) Polypropelene UL1738 “Venting systems for gas-burning appliances, Categories II, III, IV” ULC S636 “Standard for Type BH gas venting systems” Class IIC 110ºC Combustion air intake pipe and fitting Stainless steel n.a. PVC-DWV Schedule 40 ANSI/ASTM D2661 CSA B181.1 ULC S102.2 ANSI/ASTM D2665, D1785 CSA B137.3, B181.2 ANSI/ASTM F441 CPVC Schedule 40 ANSI/ASTM D2661 CSA B181.1 ULC S102.2 ANSI/ASTM D2665, D1785 CSA B137.3, B181.2 ANSI/ASTM F441 ABS-DWV Schedule 40 ANSI/ASTM D2661 CSA B181.1 ULC S102.2 ANSI/ASTM D2665, D1785 CSA B137.3, B181.2 ANSI/ASTM F441 PP(s) Polypropelene UL1738 “Venting systems for gas-burning appliances, Categories II, III, IV” ULC S636 “Standard for Type BH gas venting systems” Class IIC 110ºC PVC ANSI/ASTM D2564 CSA B137.3 CPVC ANSI/ASTM F493 CSA B137.6 ABS ANSI/ASTM D2235 CSA B181.1/B182.1 CAUTION On the job site, ensure that non-listed combustion air pipe materials are not inadvertently used instead of listed vent pipe material. 46 CAUTION Do not use cellular (foam) core pipe material to vent this Vitocrossal boiler. 5776 774 - 05 Pipe cement, primer (for combustion air intake pipe) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Venting Information Venting (continued) Vent termination location requirements (for installations in Canada) The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2. The flexible vent pipe can only be used in vertical installations. A vent must NOT terminate... 1.....directly above a paved sidewalk or paved driveway which is located between two single-family dwellings and serves both dwellings. 2.....less than 7 ft. (2.13 m) above a paved sidewalk or a paved driveway located on public property. 3.....within 6 ft. (1.83 m) of a mechanical air supply inlet*1 to any building (dryer vents, non-sealed combustion furnace and hot water heater vents are considered to be mechanical air inlets). 4.....above a meter/regulator assembly within 3 ft. (0.9 m) horizontally of the vertical centerline of the regulator vent outlet and to a maximum vertical distance of 15 ft. (4.5 m). 5.....within 3 ft. (0.9 m) of any gas service regulator vent outlet. 6.....less than 1 ft. (0.3 m) above grade level or anticipated snow level (consult local building authorities or local weather office). Locate the vent termination in such a way that it cannot be blocked by snow. 7.....within the following distances of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance: 8.....underneath a veranda, porch or deck, unless: the veranda, porch, or deck is fully open on a minimum of two sides beneath the floor, and the distance between the top of the vent termination and the underside of the veranda, porch, or deck is greater than 1 ft. (0.3 m). 9.....in areas where condensation may cause problems, such as above planters, patios, or adjacent to windows where flue gases may cause fogging. 10....within 3 ft. (0.9 m) to the property line (advisable, not mandatory; please check with local building authorities and municipal bylaws). 11....at a location where ice formation on the ground can present a hazard. 12....so that the flue gases are directed toward brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the flue gases. 13....where discharging hot flue gases may cause property damage or personal injury. 14....within 3 ft. (0.9 m) from an inside corner of outside walls. *1 Including heat recovery units. 1 ft. (0.3 m) for inputs up to and including 100 000 Btu/h / 30 kW. 3 ft. (0.9 m) for input exceeding 100 000 Btu/h / 30 kW. Vent Termination Location Requirements (for installations in the U.S.A.) The vent must be installed observing local regulations in addition to National Codes, ANSI-Z223.1 or NFPA 54. The flexible vent pipe can only be used in vertical installations. A vent must NOT terminate... 1.....less than 7 ft. (2.13 m) above a paved sidewalk or a paved driveway located on public property. 7.....within 3 ft. (0.9 m) to the property line (advisable, not mandatory; please check with local building authorities and municipal bylaws). 2....within 4 ft. (1.2.m) horizontally from service regulator vents, electric and gas meters as well as relief equipment. 8.....at a location where ice formation on the ground can present a hazard. 3....at least 3 ft. (0.9 m) above any forced air inlet located within 10 ft. (3 m). 9.....so that the flue gases are directed toward brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the flue gases. 4.....less than 1 ft. (0.3 m) above grade level or anticipated snow level (consult local building authorities or local weather office). Locate the vent termination in such a way that it cannot be blocked by snow. 5776 774 - 05 6.....in areas where condensation may cause problems, such as above planters, patios, or adjacent to windows where flue gases may cause fogging. 5.....within 1 ft. (0.3 m) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion inlet of any other appliance. 10....where discharging hot flue gases may cause property damage or personal injury. 11....within 3 ft. (0.9 m) from an inside corner of outside walls. 47 Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Venting Information (continued) Flashing and storm collar installation Flashings and storm collars are field supplied. Flashings and storm collars suitable for Type B vent materials (or better) may be used. To obtain flashings and storm collars, please contact your local vent material supplier. Follow the installation instructions supplied by the special venting manufacturer. Follow local codes to properly isolate the exhaust vent pipe when passing through floors, ceiling and roof. Always check the marking on the pipe to make sure you are using the correct material. Additional Requirements for Stainless Steel Vent Pipe Material M&G / Duravent www.duravent.com ICC - Industrial Chimney Co. www.icc-rsf.com Selkirk Canada Corporation www.selkirkchimney.com Novaflex www.flexmaster.com Security Chimneys International Ltd. www.securitychimneys.com Enervex Inc. (formerly Exhausto) www.enervex.com Jeremias Inc. www.jeremiasinc.com Van-Packer Co. Inc. www.vpstack.com Note: For SS venting system order transition adaptors from the above mentioned suppliers. Use stainless steel venting system (UL/ULC listed for category IV) for horizontal or vertical venting of the Vitocrossal boilers. Contact one of the suppliers (see listing on right) to order. Prior to installation, check that the correct single-wall vent parts were ordered and supplied. Exhaust vent/air intake connection to boiler The vent connection to the Vitocrossal boiler must be made with the starter stainless steel adaptor (supplied by others). Combustion air intake If using room air-independent venting system, the combustion air intake kit must be used. Connect the air intake pipe (from outdoors) to the adaptor provided. If room air-dependent venting system is used, the air is drawn into the burner inlet through the combustion air inlet screens located on the side of the boiler. IMPORTANT For exhaust vent pipe material: Do not use any other vent material. WARNING 48 5776 774 - 05 The use of vent material other than listed UL/ULC stainless steel and PPs positive pressure vent pipe and fittings can cause property damage, severe personal injury and/or loss of life. Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material Requirements for PP(s) and stainless steel The venting system must be installed by a licensed professional heating contractor familiar with the operation and maintenance of heating appliances and venting. Before installing, ensure that the complete installation literature has been read. Failure to follow proper installation procedures as stated in these instructions, including vent pitch and proper appliance connections, may violate local, provincial/state, or national codes and cause unsafe conditions which may lead to severe property damage or personal injury. The venting system must be installed in accordance with local building code requirements as well as national codes. For installations in Canada use CAN/CSA-B149.1 Natural Gas Installation Code or CAN/CSA-B149.2 Propane Installation Code as applicable; in the U.S. use the National Fuel Gas Code ANSI Z223.1 or NFPA Standard 54. To ensure safe operation of the appliance, Viessmann recommends that the system be inspected once a year by a qualified service technician. Every venting system must be planned and installed for optimum performance and safety. These Installation Instructions are designed to help you determine venting requirements and limitations with respect to installation. Please read and follow these instructions carefully. It is the responsibility of the installer to contact local building and fire officials concerning any installation restrictions and/or inspection requirements that may apply. Permits may be required before commencement of the installation. The vent termination for side wall vent installations should be located on a wall that is least affected by prevailing winds. High winds may affect boiler operation and/or degrade the exterior finish of the wall. They may also cause recirculation of the appliance’s own flue products. Recirculation of flue products can result in poor combustion and inlet condensation problems. If wind is a problem, steps must be taken to shield the vent termination from high winds, such as building a fence or planting shrubs. Ensure that the total equivalent vent length is not exceeded. Because of its sealed combustion chamber, the Vitocrossal 300, CA3 gas-fired condensing boiler is suitable for operation with direct vent room air independent operation (when using air intake system). IMPORTANT Potential gaps between the vent/air intake pipes and the surrounding construction which may cause air, rain or flue gases to leak into the wall or the building, must be sealed with approved sealant /caulking to prevent leakage of any kind. This PP(s) vent system is constructed from flame-retardant plastic [polypropylene rated for a maximum temperature of 230ºF (110ºC)]. The PP(s) venting system components must be listed to ULC S636 / UL-1738 (contact one of the venting suppliers below). DO NOT mix pipe, fittings, or joining methods from different vent system manufacturers. The vent length requirements stated in this manual (on page 59 for two pipe vent installations and page 61 for single pipe installations) must be observed. If using flexible vent or air intake pipe, reduce the max. equivalent length allowed by 25%. The PP(s) venting material can be extended (without exceeding the maximum equivalent length) beyond the outside wall of the structure, provided that the PP(s) venting material is installed in an enclosed, insulated and waterproof chase that is acceptable for outdoor installation. The vent termination location must comply with the instructions and codes stated in this manual. IMPORTANT Side wall vent installations must include a protective screen. Vent System Suppliers Use special venting system (UL/ULC listed for Category IV) for exhaust vent material of the Vitocrossal boilers. Contact one of the following suppliers to order parts. Both suppliers deliver PP(s) rigid and flexible vents in a variety of sizes. M&G / Duravent www.duravent.com Centrotherm InnoFlue www.centrotherm.us.com 5776 774 - 05 Use only material listed in table on page 46, entitled “Approved venting materials”. The remaining space surrounding a chimney liner, gas vent, or special gas vent or plastic piping installed within a masonry, metal or factory-built flue shall not be used to supply combustion air to the boiler. A separate combustion air intake pipe routed back to the boiler can be used in the remaining space if required, the boiler venting system is approved for zero clearance, and can be run directly beside the combustion air intake pipe. 49 Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vent Requirements Provisions for combustion and ventilation air must be made in accordance with CAN/CSA-B149.1 or .2 Natural Gas Installation Codes (latest edition) (for installations in Canada) or in accordance with sections for Combustion and Ventilation Air, of the National Fuel Gas Code, ANSI Z223.1 (latest edition) or applicable provisions of local codes (for installations in the U.S.A.) Follow local codes to properly isolate the vent pipe when passing through floors, ceilings and roof. Whenever possible, install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area. Refer to national codes for duct sizing. Round ducts may be used. The boiler must be vented and supplied with combustion air and exhaust vents as described in this section. Ensure the vent and combustion air supply comply with these instructions. (See also page 47). WARNING Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, which can cause severe personal injury or loss of life. The Vitocrossal 300, CA3 boiler location should never be under negative pressure. Exhaust fans, attic fans, or dryer fans may cause air to be exhausted at a rate higher than the air can enter the structure for safe combustion. Corrective action must be taken to ensure enough air is available. Never cover the boiler or store debris or other materials near the boiler, or in any way block the flow of adequate fresh combustion air to the boiler. 50 If boiler is installed in a confined space (a space with a volume of less than 50 cubic feet per 1000 Btu/h of gas input for all fuel burning equipment) or building layout is unusually tight, adequate air for combustion must be provided by two openings: one located about 6 in. below the ceiling, the other about 6 in. above the floor. When communicating directly with the outside, each opening must have a minimum free area of one square inch per 2000 Btu/h of gas input. When all combustion air is provided by openings in doors, etc. to adjoining spaces having adequate infiltration, each opening must have a minimum free area of one square inch per 1000 Btu/h of gas input, but not less than 100 in2. You must know the free area of louvers used to cover up the combustion and ventilation openings in closet installations. If you do not know the free area, assume 20% for wood louvers and 60-75% free area for metal louvers. When using louvers, the openings have to be made larger. For example, a free 14 in. x 6 in. (356 mm x 152 mm) opening becomes a 14 in. x 10 in. (356 mm x 254 mm) opening for a grill containing metal louvers. CAUTION Do not store chemicals containing chlorine or other corrosive materials near the boiler, such as bleach, cleaning solvents, detergents, acids, hair spray, spray cans, paint thinners, paint, water softener salt, perchloroethylene, or carbon tetra chloride. 5776 774 - 05 Combustion air supply, room air dependent application only The Vitocrossal 300, CA3 boiler requires fresh air for safe operation and must be installed in a mechanical room where there are provisions for adequate combustion and ventilation air. Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Direct Venting (Two Pipe System) Side wall vent termination [stainless steel, CPVC or PP(s)] IMPORTANT Stainless steel or plastic mesh The exhaust vent/air intake system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the “Natural Gas and Propane Installation Code” CAN/CSA-B149.1 (Canada), or the “National Fuel Gas Code” ANSI Z223.1 (NFPA 54) (U.S.A.). Min. 36 in. (915 mm) IMPORTANT Intake terminal 90o Min. 12 in. (305 mm) Exhaust vent terminal 45o Grade or max. snow level For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer). WARNING Vent termination must be at least 12 in. (305 mm) above the anticipated snow level (consult your local building authorities or local weather office). Locate vent termination in such a way that it cannot be blocked by snow. Min. 2 in. (50 mm) Max. 36 in. (915 mm) Vent Min. 12 in. (305 mm) Air Min. 2 in. (50 mm) Support bracket Termination elbow with screen Side wall Max. 36 in. Vent (915 mm) * Min. 12 in. (305 mm) 5776 774 - 05 Caulk Grade or max. snow level * Field fabricated vent riser 51 Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Side Wall Venting Side wall vent termination [stainless steel or PP(s)] IMPORTANT For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer). Min. 12 in. (305 mm) Exhaust vent terminal 90o Grade or max. snow level Min. 2 in. (50 mm) Max. 36 in. (915 mm) Flue Support bracket Termination elbow with screen Side wall Max. 36 in. Vent (915 mm) * Min. 12 in. (305 mm) Grade or max. snow level * Field fabricated vent riser 52 5776 774 - 05 Caulk Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Component Installation Guide Flashing and storm collar installation Flashings and storm collars are field supplied. Flashings and storm collars suitable for Type B vent materials (or better) may be used. To obtain flashings and storm collars, please contact your local vent material supplier. Follow the installation instructions supplied by the special venting manufacturer. Vent Termination Location Requirements - Vertical The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2 (for installations in Canada) or ANSI-Z223.1 or NFPA 54 (for installations in the U.S.A.). WARNING For sloped roof applications with distance b greater than 18 in. (450 mm) Vent termination must be at least 12 in. (305 mm) above the anticipated snow level (consult your local building authorities or local weather office). Locate vent termination in such a way that it cannot be blocked by snow. A vent used in a special venting system with positive vent pressure and passing through a roof shall extend at least 18 in. (450 mm) above the highest point where it passes through the roof and any other obstruction within a horizontal distance of 18 in. (450 mm). The special vent system shall not be routed into, through, or within any other vent such as an existing masonry or factory-built chimney. IMPORTANT A masonry chimney flue may be used to route the venting system only if no other appliance is vented in the same flue. For sloped roof applications with distance b less than 18 in. (450 mm) 5776 774 - 05 For flat roof applications a b minimum 18 in. (450 mm) <18 in. (450 mm) 53 Venting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Installation of Support System - PP(s) Bracing Contact your local vent material supplier for more information specific to your installation. Braces are required to stabilize an installation. There are different types and their use and spacing vary. The following types of braces are available at your local vent material supplier: wall band wall band extension guy wire band roof brace. IMPORTANT Ensure that the venting system is properly supported; the boiler is not designed to support the weight of the venting system. Vent system suppliers To order approved PP(s) vent system contact the following suppliers. 54 For exhaust vent pipe material: Use only ULC S-636 / UL 1738 vent material. The venting system must be securely supported by a support system suitable for the weight and design of the materials employed. Contact your vent material supplier for more information specific to your installation. Supports are used to transfer the weight of an installation to the building structure. There are different types of supports and their capacity varies with each type and diameter. The following support types are available at your local vent material supplier: anchor plate wall support roof support floor support suspension band (hanger). Centrotherm InnoFlue www.centrotherm.us.com 5776 774 - 05 M&G / Duravent www.duravent.com IMPORTANT Venting Options - Stainless Steel/PP(s) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Two Pipe System - Vertical Exhaust/Vertical Air Intake Flue Air a - Equivalent exhaust length b - Equivalent air intake length (see chart for max. air intake length) Vertical intake and exhaust Vitocrossal 300 CA3 Boiler model 3.5 4.0 Combustion air intake diameter in. (mm) 12 (300) 12 (300) 12 (300) 12 (300) Exhaust vent diameter in. (mm) 12 (300) 14 (350) 12 (300) 14 (350) Max. combustion air intake length ft. (m) 66 (20) 131 (40) 50 (15) 66 (20) Max. total equivilent length (a+b) ft. (m) 198 (60) 198 (60) 115 (35) 198 (60) Vertical intake and exhaust Vitocrossal 300 CA3 Boiler model 5.0 6.0 Combustion air intake diameter in. (mm) 16 (400) 16 (400) Exhaust vent diameter in. (mm) 16 (400) 16 (400) Max. combustion air intake length ft. (m) 198 (60) 164 (50) Max. total equivilent length (a+b) ft. (m) 198 (60) 198 (60) 5776 774 - 05 Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%. 55 Venting Options - Stainless Steel/PP(s) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Two Pipe System - Vertical Exhaust/Vertical Air Intake (continued) IMPORTANT All PP(s) vent termination elbows, must be secured in place as specified by manufacturer. IMPORTANT For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer). Legend A Support system B Flashings C Exhaust with screen D Combustion air intake with screen Dimensions a min. 18 in. / max. 48 in. b min. 0 in. c min. 12 in. d 6 in. over max. local snow level (check with your local weather office for details). Vertical Vent Installation Flat Roof 56 5776 774 - 05 Vertical Vent Installation Sloped Roof Venting Options - Stainless Steel/PP(s) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Two Pipe System - Horizontal Exhaust/Horizontal Air Intake Flue Min. 36 in. (915 mm) Air a - Equivalent exhaust length b - Equivalent air intake length (see chart for max. air intake length) Horizontal intake and exhaust Vitocrossal 300 CA3 Boiler model 3.5 4.0 Combustion air intake diameter in. (mm) 12 (300) 12 (300) 12 (300) 12 (300) 14 (350) Exhaust vent diameter in. (mm) 12 (300) 14 (350) 12 (300) 14 (350) 14 (350) Max. combustion air intake length ft. (m) 50 (15) 66 (20) 50 (15) 50 (15) 131 (40) Max. total equivilent length (a+b) ft. (m) 99 (30) 198 (60) 66 (20) 149 (45) 198 (60) Horizontal intake and exhaust Vitocrossal 300 CA3 Boiler model 5.0 6.0 Combustion air intake diameter in. (mm) 16 (400) 16 (400) Exhaust vent diameter in. (mm) 16 (400) 16 (400) Max. combustion air intake length ft. (m) 131 (40) 50 (15) Max. total equivilent length (a+b) ft. (m) 198 (60) 180 (55) 5776 774 - 05 Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%. 57 Venting Options - Stainless Steel/PP(s) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Two Pipe System - Vertical Exhaust/Horizontal Air Intake Flue Air a - Equivalent exhaust length b - Equivalent air intake length (see chart for max. air intake length) Horizontal intake and vertical exhaust Vitocrossal 300 CA3 Boiler model 3.5 4.0 Combustion air intake diameter in. (mm) 12 (300) 12 (300) 12 (300) 12 (300) Exhaust vent diameter in. (mm) 12 (300) 14 (350) 12 (300) 14 (350) Max. combustion air intake length ft. (m) 66 (20) 131 (40) 50 (15) 66 (20) Max. total equivilent length (a+b) ft. (m) 198 (60) 198 (60) 115 (35) 198 (60) Horizontal intake and vertical exhaust Vitocrossal 300 CA3 Boiler model 5.0 6.0 Combustion air intake diameter in. (mm) 16 (400) 16 (400) Exhaust vent diameter in. (mm) 16 (400) 16 (400) Max. combustion air intake length ft. (m) 198 (60) 164 (50) Max. total equivilent length (a+b) ft. (m) 198 (60) 198 (60) 58 5776 774 - 05 Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Single Pipe System - Vertical Exhaust/Room Air Dependant Flue Room Combustion Air Opening Air Air a - Equivalent exhaust length Vertical exhaust/room air dependant Vitocrossal 300 CA3 Boiler model Exhaust vent diameter Max. total equivilent length (a+b) 3.5 4.0 in. (mm) 12 (300) 14 (350) 12 (300) 14 (350) ft. (m) 198 (60) 198 (60) 198 (60) 198 (60) Vertical exhaust/room air dependant Vitocrossal 300 CA3 Boiler model Exhaust vent diameter Max. total equivilent length (a+b) 5.0 6.0 in. (mm) 16 (400) 16 (400) ft. (m) 198 (60) 198 (60) 5776 774 - 05 Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%. 59 Venting Options - Stainless Steel/PP(s) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Single Pipe System - Horizontal Exhaust/Room Air Dependant Room Combustion Air Opening Air Air Flue a - Equivalent exhaust length Horizontal exhaust/room air dependant Vitocrossal 300 CA3 Boiler model Exhaust vent diameter Max. total equivilent length (a+b) 3.5 4.0 in. (mm) 12 (300) 14 (350) 12 (300) 14 (350) ft. (m) 164 (50) 198 (60) 115 (35) 198 (60) Horizontal exhaust/room air dependant Vitocrossal 300 CA3 Boiler model Exhaust vent diameter Max. total equivilent length (a+b) 5.0 6.0 in. (mm) 16 (400) 16 (400) ft. (m) 198 (60) 198 (60) 60 5776 774 - 05 Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Multiple Boiler Installations Horizontal vent termination 36 in. min. (915 mm min.) Note: 36 in. (915 mm) minimum distance apart for horizontal vent terminations. Vertical vent termination 6 in. min. (150 mm min.) 4 in. min. (100 mm min.) 5776 774 - 05 Note: 4 in. (100 mm) minimum distance apart for vertical vent terminations. 61 General Service Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Service Equipment Cleaning supplies Plastic hand brush Cleaning/service brush Vacuum cleaner Clean rags Testing/analysis equipment (use only calibrated equipment) 62 Flue gas analyzer to measure % CO2 or O2 (e.g. Bacharach fluid samplers or a suitable electronic analyzer). Multimeter to measure 0-120VAC, 0-20 amps AC and 0-100 microamps DC. Pressure gage to measure gas pressure 0 - 28 "w.c. A non-electric Magnehelic pressure gage (0 - 10 psig) may also be used. Carbon monoxide measuring equipment (0 - 400 ppm). Bacharach calculator or suitable tables to calculate efficiency. Stack thermometer dial settings range 0 to 250ºF (121ºC). d in. NPT male to ¼ in. barb adaptor fitting, as well as tubing for pressure measurement. Technical information The following is a list of literature applicable to the Vitocrossal 300, CA3 boiler: Installation/Service Instructions Operating Instructions For installation of the heating system, please refer also to the technical literature of other System Technology devices: Installation Instructions for Viessmann boiler control Installation Instructions for Viessmann indirect-fired hot water storage tank(s) Installation Instructions for burner and accessories Replacement parts For a complete listing of replacement components, please see Parts List starting on page 169 of these instructions. Order replacement components from your Viessmann distributor. CAUTION Use only original Viessmann recommended components when replacing defective parts. Installation of incorrect replacement parts can cause hazardous operation and will void warranty. 5776 774 - 05 Tools Assortment of flathead and Phillips screwdrivers Pipe wrenches Open-ended wrenches Pipe sealant Assortment of Hex keys Flashlight Approved leak detection fluid for natural gas and propane gas Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service General Service Information Important Regulatory and Installation Requirements Instructing the system user The installer of the system is responsible to ensure the system operator/ultimate owner is made familiar with the functioning of the system, its activation, and its shutdown. Initial start-up Initial start-up must be performed by a qualified heating contractor. Completion of the Maintenance Record by the heating contractor is also required. Working on the equipment The installation, adjustment, service, and maintenance of this equipment must be done by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water heating systems. There are no user serviceable parts on this equipment. Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work. The following topics must be covered: Proper system operation sequence. Explain the equipment as well as the need for combustion air. Demonstrate an emergency shut-down, what to do and what not. Explain that there is no substitute for proper maintenance to help ensure safe operation. The Maintenance Record is located on page 220 of this manual. Please carefully read this manual prior to attempting start-up, maintenance or service. Any warranty is null and void if these instructions are not followed. For information regarding other Viessmann System Technology componentry, please reference documentation of the respective product. Viessmann offers frequent installation and service seminars to familiarize our partners with our products. Please inquire. The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. These include low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc. Technical literature Literature applicable to all aspects of the Vitocrossal 300, CA3: - Technical Data Manual - Installation and Service Instructions - Operating Instructions - Wiring diagrams Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact Viessmann for additional copies. 5776 774 - 05 Additional applicable literature: - Viessmann boiler controls manuals 63 General Service Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Safety Instructions Target group These instructions are intended exclusively for qualified contractors. ■ Work on gas installations must only be carried out by a licensed professional heating contractor. ■ 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. ■ This appliance has not been designed to be operated by individuals other than those qualified and trained. Regulations Observe the following when working on this system: ■ Statutory regulations regarding the prevention of accidents ■ Statutory regulations regarding environmental protection ■ Codes of practice of the relevant trade associations. If you smell gas WARNING Escaping gas can lead to explosions which may result in serious injury. ■ Do not smoke. Prevent naked flames and sparks. Do not press any switches for lights or electrical appliances. ■ Close the gas shut-off valve. ■ Open windows and doors. ■ Remove all people from the danger zone. ■ Notify your gas or electricity supply utility from outside the building. ■ Shut off the electricity supply to the building from a safe place (outside the building). If you smell flue gas WARNING Flue gas can lead to life threatening poisoning. ■ Shut down the heating system. ■ Ventilate boiler room. ■ Close all doors in the living space Auxiliary components, spare and wearing parts Note: Spare and wearing parts that have not been tested together with the system can compromise its function. Installing non-authorised components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only original spare parts supplied or approved by Viessmann. Checking the high limit safety cut-out setting The high limit safety cut-out is preset to 210°F (99°C). If this temperature needs to be changed, this can only be done by changing the coding card. Refer to the control section of the Installation Instructions. CSD-1 Field Testing of High Limit Switches for Vitocrossal 300, CA3 boilers – where required by law. As per ASME Boiler and Pressure Vessel Code, section IV, subsection HG-613 TEMPERATURE CONTROL requirements, Vitocrossal 300, CA3 hot water boilers are protected from over-temperature by two temperatureoperated controls. These temperature control devices conform to Standards for Limit Controls, and are accepted by CSA, a nationally recognized testing agency. Each boiler is equipped with a manual reset high temperature limit control and a temperature control that will cut off fuel supply when the system water temperature reaches a preset operating temperature. VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM. The Vitocrossal 300, CA3 boilers are equipped with 2 RTD temperature sensors that when activated on temperature rise (high fixed limit of 210°F (99°C) disable the burners to operate. The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control. Repair work Note: Repairing components that fulfil a safety function can compromise the safe operation of your system. Replace faulty components only with original Viessmann spare parts. 64 5776 774 - 05 Working on the system ■ Where gas is used as the fuel, close the main gas shut-off valve and safeguard it against unintentional reopening. ■ Isolate the system from the power supply (e.g. at the separate fuse or a main switch) and check that it is de-energized. ■ Safeguard the system against reconnection. Note: Electronic assemblies can be damaged by electrostatic discharges. Before beginning work, touch grounded objects, such as heating or water pipes, to discharge static loads. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Safety Instructions General Service Information (continued) Note: Each boiler section is equipped with its own fixed high limit. Each fixed high limit must be tested individually. Fixed High Limit test procedure: 1. Use the emission test switch to generate call for heat. Refer to Vitotronic 300 GW6C Operating Instructions. 2. As described in the table on page 159, adjust item #4 “Max. boiler water temperature” under menu 6 of each burner control (GC310) to a max. setting of 243°F (117°C), as an example, higher than fixed high limit temperature setting [factory default setting is 203°F (95°C)]. For testing of the adjustable limit ‘Max. boiler temperature’ for a reduced temp. value as required (e.g. 122°F (50°C). 3. Press/activate emission test switch if applicable, the burners will start. 4. Gradually and slowly throttle the water flow to the boiler. 5. Observe temperature on the GW6C control. 6. Once the temperature reached the fixed high limit setting, burner control will have a hard lock out with F F2 fault displayed. Burner fan stays on for 10 min. The fault can only be manually reset once the water temperature in the boiler drops. 7. Reset to original settings as needed (item #4 under submenu 6). Menu item “6“ is used to change the following operating parameters: (see page 159 for more detail) 5776 774 - 05 Sub-menu Parameter Item 1 Maximum operational input 2 Gas type 3 Not assigned 4 5 6 Runtime optimization 0 Reset all operating parameters to their factory set condition. Units/Scale Factory set condition % of rated input 100% 0=NG (natural gas) 1=LPG (liquid propane gas) -- -- Maximum boiler water temperature from 41 to 260°F (5 to 127°C) 203°F (95°C) Integral threshold value of controller In Kmin from 1 to 255 30 Kmin 0=minimum pause 1=integral method 1 -- -- 65 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Filling the Heating System with Water and Ventilating Valve closed IMPORTANT See page 101 for water quality requirements. 1. Fill Vitocrossal 300, CA3 with fully softened water. 2. Enter the fill quantity, water softness and pH-value. Push actuator release button To open valve To close valve 3. Before filling push the actuator release button and open each isolation valve (located near the return header of each boiler section). Valve open 4. When fill is complete push the actuator release button and close each isolation valve (located near the return header of each boiler section). Push actuator release button Filling Condensate Trap with Water 1. Remove the siphon cup A and fill with water (otherwise flue gas may escape). 2. Check that the condensate can drain freely. 3. Refit the siphon cup A. Note: The hose connection to the on-site condensate system or to the neutralizing system must not be permitted to sag; support hose where required. Checking the Type of Gas IMPORTANT 1. The burners are factory set for operation with natural gas. 2. Record gas type in record (on page 219). 66 5776 774 - 05 The heating system is equipped for operation with natural gas. Switching over to another type of gas is not possible. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Service Operating the System Commissioning the system WARNING Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury, or loss of life. Flue gases may contain deadly carbon monoxide. Gas type characteristics The Vitocrossal 300 CA3 boiler is for use with gases whose characteristics fall within the following ranges. Natural Gas Heating value (gross) Btu/ft3 970 to 1100 Specific gravity 0.57 to 0.70 Ultimate carbon dioxide (CO2) % 11.7 to 12.2 See the control section of the Installation Instructions and neutralizing system Operating Instructions. 1. Check the heating system pressure. Permissible boiler operating pressure: 160 psi. 2. Check the gas supply pressure. Permissible gas pressure 4-14 “w.c. 3. Open the gas line shut-off valves. 4. Switch ON the internal power disconnect switch. 5. Switch ON the main power (breakers). 6. Switch ON system ON/OFF switch at the control unit. If fault indicator on the control unit illuminates and burner control unit display A flashes, first press reset button R B on the burner control unit. Note: The system can enter a fault state during commissioning if there is insufficient gas in the supply line (the fault indicator on the control unit illuminates). Purge the gas supply line again and reset the burner control unit. Remove air from the gas line with an approved gas purge burner or vent outdoors. 7. Switch ON the individual section control power switches (the control display will show system activation). 8. Match the coding card at the burner control unit according to the chart on this page. Also refer to page 84. See the control section of the Installation Instructions and neutralizing system Operating Instructions. 9. Check the function of the neutralizing system. Note: Neutralizing system operating instructions. 10.Check all gaskets and plugs, and retighten if necessary. Note: We recommend you check all connections on the heating water side for leaks after approximately 500 hours initial run (see page 102). 5776 774 - 05 11. Check the boiler door a few days after commissioning and retighten all screws. 67 Service Operating the System Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) The control unit is pre-set, however several codings must be set individually. 1. Activate the main switch and all network switches on the control units. 2. Activate switch on the control unit. Start-up begins automatically. The following settings may be changed “Language” “Date and time” “Temperature units” “System layout” “Elevation” 3. Confirm with OK, after which the prompt will appear: “Do you want to make further changes”. IMPORTANT With / , you can switch between codes. After you have scrolled through all the codes, a message appears to end operations. Legend Refer to the Vitocrossal 300 CA3 Operating Instructions. A System and lead boiler section 1 control unit B Boiler section 2 control unit C Boiler section 3 control unit (5.0 and 6.0 only) IMPORTANT 68 5776 774 - 05 Control unit A assumes the function of the boiler and heating circuit control and of the system boiler section 1 control unit. Referred to below as Cascade control unit.“Boiler section 1 + cascade” appears on the display. The other control units assume the function of a lag boiler control unit. Referred to as Boiler section 2/boiler section 3 control unit. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Operating the System (continued) IMPORTANT During the initial start-up, the equipment can go into a fault state due to insufficient gas in the gas pipe (Fault lamp lights up on the control unit). Ventilate gas line once again and reset burner control unit. See “Burner control unit” chapter. IMPORTANT Adjusting the coding Check all addresses in Coding level 1 and adjust if required. See “Coding” chapter. If the fault indicator lights up on the control unit and the display on the burner control unit is blinking, reset burner control unit. To reset, press the reset button R on the burner control unit. If the fault continues, the supply side of the combination gas valve may be blocked due to work on the gas pipe. See the following chapter to adjust coding. Burner will start up after a 3 min delay. Function “Max operational output” “Gas type” “Altitude” “Design” “System design” “Consecutive boiler number in multi boiler systems” “Number of boilers connected to the cascade” “Cascade” “LON participant number” “Control strategy” Group “Boiler control unit” “General” “Cascade” “General” “Cascade” “Boiler” Coding 02 03 04 0A 00 35 77 3C 07 5776 774 - 05 Check the following coding addresses in Coding level 2 and adjust accordingly. See Chapter “Coding” for procedural steps and overview on code setting. Function Group Coding “Single boiler and multiple boiler system” “Boiler” 01 “Connection at plug 29” “Viessmann system number” With LON communication module: LON Participants monitoring” “Connection at plug 52A1” “With LON communication module” (control unit is fault manager) “Central control of heating circuits” “Viessmann system number” “With LON communication module: Monitoring LON participants” “Permanent last boiler” “Permanent boiler section 1” “Storage tank heating, hysteresis” “General” “General” “General” “General” “General” “General” “General” “General” “Cascade” “Cascade” “DHW” 4D 98 9C 4E 79 7A 98 9C 3A 39 55 69 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Adjusting the Heating Curve Boiler water or supply temperature Slope The heating curves represent the relationship between the outdoor temperature and the boiler water or supply temperature. Simplified: The lower the outdoor temperature, the higher the boiler water or supply temperature. The boiler water or supply temperature in turn affects the room temperature. Settings in the factory set condition: H Slope = 1.4 H Shift = 0 Room set-point temperature Outdoor temperature For outdoor temperature 7°F (−14°C) Legend A Underfloor heating system, slope 0.2 to 0.8 B Low temperature heating system, slope 0.8 to 1.6 C Heating systems with a boiler water temperature in excess of 167°F (75°C), slope greater than 1.6 Standard set room temperature Selecting the set room temperature Individually adjustable for each heating circuit. The heating curve is offset along the set room temperature axis. With the heating circuit pump logic function enabled, the curve modifies the starting and stopping characteristics of the heating circuit pump. Changing the standard set room temperature Refer to the Vitotronic 300 GW6C Operating Instructions. Adjustment of the standard set room temperature from 68 to 79°F (20 to 26°C). 70 5776 774 - 05 Legend A Boiler water temperature or supply temperature B Outdoor temperature C Set room temperature D Heating circuit pump “Off” E Heating circuit pump “On” Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Adjusting the Heating Curve (continued) Reduced set room temperature Changing the standard set room temperature Refer to the Vitocrossal 300 CA3 Operating Instructions. Adjustment of the reduced set room temperature from 37 to 52°F (3 to 14°C). Legend Boiler water temperature or supply temperature Outdoor temperature Set room temperature Heating circuit pump “Off” Heating circuit pump “On” A B C D E Changing the slope and shift Individually adjustable for each heating circuit. Boiler water or supply temperature From the home screen tap the following buttons: 1. Tap “Menu”. 2. “Heating circuit 1”, “Heating circuit 2” or “Heating circuit 3” as the required heating circuit. 3. Heating. 4. “Heating curve”. 5. +/– for the required value for “Slope” or “Shift”. 6. Tap OK to confirm. Outdoor temperature Legend A Changing the slope B Changing the shift (vertical parallel offset of the heating curve) 5776 774 - 05 Example: Heating curve setting with slope 1.5: 71 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Integrating the Control Unit into the LON The LON communication module is factory installed. Vitotronic 200-H: The LON communication module (accessory) must be plugged in. 72 The same participant number may not be assigned twice within a LON. Example for a multiple-boiler system: Within a LON, the system numbers (Coding “98” in the “General” group) must be the same. Only one control unit may be encoded as fault manager. The data transfer via LON can take up to several minutes. A B C D E Multiple boiler system Set coding “01:2” in the “Boiler” group Multiple boiler system Set coding “01:2” in the “Boiler” group. Multiple boiler system Set coding “01:2” in the “Boiler” group. -- -- Boiler number 2 Set coding “07:2” in the “Boiler” group. Boiler number 3 Set coding “07:3” in the “Boiler” group Boiler number 1 Coding “07:1” in the “Boiler” group -- -- — — Number of connected boilers Set coding “35:1” to “35:8” in the “Cascade” group. -- -- Participant No. 2. Coding “77:2” in the “General” group. Participant No. 3. Set coding “77:3” in the “General” group. Participant No. 1. Coding “77:1” in the “General” group. Participant No. 99. Participant No. 10. Coding “77:10” in the “General” group. Control unit is not fault manager. Coding “79:0” in the “General” group. Control unit is not fault manager. Coding “79:0” in the “General” group. Control unit is fault manager. Coding “79:1” in the “General” group. Appliance is fault manager. Control unit is not fault manager. Coding “79:0” in the “General” group. Appliance receives time. Control unit receives time. Set coding “81:3” in the “General” group. -- -- Control unit transmits time. Coding “7b:1” in the “General” group. -- -- Control unit transmits outdoor temperature. Coding “97:2” in the “General” group. -- Control unit receives outdoor temperature. Set coding „97:1“ in the “General” group. Viessmann system Viessmann system number, coding “98:1” number, coding “98:1” in the “General” group. in the “General” group. Viessmann system number, coding “98:1” in the “General” group. -- Viessmann system number, coding “98:1” in the “General” group. LON Participant fault monitoring Coding “9C:20” in the “General” group. LON Participant fault monitoring Coding “9C:20” in the “General” group. -- LON Participant fault monitoring Coding “9C:20” in the “General” group. LON Participant fault monitoring Coding “9C:20” in the “General” group. 5776 774 - 05 Legend A Boiler section 2/boiler section 3 (5.0 and 6.0 only) control unit B Boiler section 2/boiler section 3 (5.0 and 6.0 only) control unit C Boiler section 1 and cascade control unit D Vitocom 100 E Vitotronic 200-H: F CA3 5.0 or 6.0 G CA3 3.5 or 4.0 Note: Combination of CA3 boilers cannot exceed 8 boiler sections. Refer to the Vitotronic 200-H Installation and Service Instructions. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Integrating the Control Unit into the LON (continued) Carrying out a LON participant check The participant check is used to test communication with the system devices connected to the fault manager. Preconditions: H The control unit must be programmed as fault manager (coding “79:1” in the “General” group). H The LON participant no. must be programmed in all control units. H The LON participant list in the fault manager must be up to date. From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “Service functions” 5. “LON participant check” The list of all connected LON participants appears. 6. Select participant and start participant check with “OK”. “Participant ...” appears on the display” Check running”. Note: During the participant check, the display for the relevant participant flashes for approx. 1 min. and displays “Wink”. H Successfully tested participants are designated with “OK”. H Unsuccessfully tested participants are designated with “Subscribe ... Check not OK”. Update the participant list with “New list” in order to carry out another participant check. Setting the Boiler Sequence Setting the boiler sequence Function “Boiler section 1 and boiler sequence changeover” “Permanent boiler section 1” “Permanent last boiler” “ECO-threshold boiler”... Coding 38 39 3A 41 to 44, 65, 6F, 74, 7D H Every boiler can be blocked or enabled subject to outdoor temperature by means of the ECO threshold. H The ECO threshold has no effect if a boiler is required to achieve the set supply temperature in the case of enabled boilers failing. H At least the boiler section 1 remains in operation when all boilers in a system would otherwise be blocked via the ECO threshold. 5776 774 - 05 Tap the following buttons: 1. “Menu” 2. “Boiler sequence” 3. Select the required boiler sequence and confirm with “OK”. 73 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Preparing for Service Work on the Boiler and Burner IMPORTANT Disconnect power and ensure system is shut down during any service work on the burner. 1. Dismantle upper panel. 2. Dismantle panels on the right side (service side) of the boiler. In order to remove the burner, dismantle the following: 3. Dismantle upper frame profile. 4. Dismantle upper side frame profile. If applicable, only on the burner that is being removed. 5. If a lifting device is to be installed, remove lower side panel. IMPORTANT A lifting mechanism is required to dismantle the burner. A lifting mechanism that can be mounted to the boiler is available as an accessory. This lifting mechanism is designed exclusively to lift out the burner. Installing the lifting mechanism Refer to the lifting mechanism Installation Instructions. Rear of boiler Front of boiler Section 1 Section 2 Section 3 Boiler model 3.5 4.0 5.0 6.0 74 Section 1 (lead) 1500 2000 1500 2000 Burner Input MBH Section 2 (lag 1) 2000 2000 1500 2000 Section 3 (lag 2) --2000 2000 5776 774 - 05 Burner Combinations Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Reducing Operational Output (if required) The burners heating output can be reduced via the individual burner control unit. As an alternative, the adjustment can be made via the burner control unit. If required, the maximum heating output of the burners can be set at 70 to 100% of the rated heating output. 1. Press button S E for longer than 2 sec. will blink. 2. Press button F until “6” appears in the display C under Service. 3. Press button S E, “6” appears in the display C under Status. 4. Press button S E, “1” appears in the display C under Status and the actual value for the maximum heating output will be indicated in % under Service. 5. Press button F or heating output. D for the desired maximum 6. Press button S E to confirm. If successfully completed, “1” appears in the display C under Service, a failed attempt results in a “0”. 7. Press button S E to make a change in operating status indicator. 5776 774 - 05 8. Press button R G. A system reboot will be initiated. 75 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking Static and Connection Pressure Static Pressure 1. Close gas shut-off valve. 2. Loosen screw in the measuring connector A do not remove. 3. Connect pressure measuring device at measuring connector A. 4. Open gas shut-off valve. 5. Measure static pressure max. 14 “w.c. 6. Record measurement reading in record (on page 219). IMPORTANT A CO2 measurement (see page 72) must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of the system. Supply pressure for NG 1. Start the burner IMPORTANT The burner is automatically ignited and starts operation after a safety time has elapsed. During initial start-up, the unit may indicate a fault because of air in the gas supply pipe. After approximately 5 seconds, press the reset button R to reset the burner. The ignition procedure is repeated. This boiler employs a direct spark ignition system. WARNING Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning could result in fire, explosion, personal injury, or death. Note: For commissioning, see page 75. Switch the burner to maximum heating output. For this, activate the emissions test switch at the boiler control unit. 2. Measure the supply pressure (running pressure). Use suitable measuring instruments calibrated with a minimum resolution of 0.04 “w.c. for measuring the supply pressure. Value must be: Note: The supply pressure should be between 4 “w.c. and 14 ”w.c. The gas pressure switch for the inlet pressure test/check is factory set to 4 ”w.c. Never alter this setting. 3. Record the actual value in the record (on page 219). 4. Close the gas shut-off valve. 5. Remove the pressure tester and close test nipple A. WARNING Ensure that there is no open flame in the room. Supply pressure with: Corrective action 76 under 4”w.c. Do not attempt adjustment. Call local gas utility 4 to 14“w.c. Start up boiler. over 14”w.c Do not attempt adjustment. Call local gas utility to decrease pressure. Boiler valve must not be exposed to pressure over 14 ”w.c. 5776 774 - 05 Natural gas Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking the Rotary Slide Valve Setting 1. Open gas shut-off valve. 2. Check the rotary slide valve setting when burners are off. The rotary slide valve windows B must be fully opened. The scale ring D must be set at “0” on the air damper actuator relative to the marking C. 3. Check whether the compensating tubing A has been connected between the gas valve and venturi mixing pipe. 4. Put burners into operation. 5. Check the setting of the rotary slide valve during the start-up phase. The rotary slide valve windows B must nearly close for approx. 5 sec. The scale ring D must be set as follows during this time: Burner model Rotary slide valve setting 5776 774 - 05 MBTU 1500 20° (close) 0° open 2000 20° (close) 0° open 77 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking the Rotary Slide Valve Setting (Continued) Checking the functioning of the shut-off damper Angle position of the switch cams: The servomotor is at setting “0” during standstill. The factory-installed settings may not be changed. Putting burners into operation Servomotor moves to 105°, levers and rods move to the left. Valve A is opened. 78 5776 774 - 05 Turning burners off Servomotor moves to setting “0”, valve A is closed. The spring on the rod is compressed approx 0.08 in. to 0.21 in. (2 to 3 mm). The valve is thus pressed against the facings. The tightness is ensured. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Measuring CO2 Content Preparing for measurement IMPORTANT When adjusting a burner only this one burner may be in operation. The other boiler unit burners must be at standstill. Take measurement readings of burners one after the other. Checking the CO2 level Preparing the test 1. Open the gas shut-off valve. 2. Start the burner with the emissions test switch enabled at the boiler control unit. 3. At the same time, press button S E and button B D and hold for longer than 2 seconds. The display will then show the following: ■ Under Status C: “P“ (= relay test) ■ Under Service C: Modulation level in % “100“ = 100% = upper heating input “0“ = 0% = lower heating input CO2 Test at the upper heating input 1. Press button Y F until the service display C has incremented to “100“(= 100%). 2. Check the CO2 level at the flue pipe. 3. If the CO2 level must be adjusted: ■ Remove cap B. ■ Turn adjusting screw A in small increments (3 mm Allen key) until the CO2 level falls within the specified range: - Turning clockwise → CO2 level falls (less gas) - Turning counter-clockwise → CO2 level rises (more gas) 4. Record the actual value in the report (on page 219). Burner model MBH 1500 5776 774 - 05 2000 Permissible CO2 content Natural gas 8.9 +0.3/-0.1% 79 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Measuring CO2 Content (Continued) Measuring CO2 at lower heating output 1. Press button D until the service indicator has dropped down to “0” (lower heating output). 2. Measure CO2 content at the flue gas pipe. IMPORTANT CO2 content in partial load must always be at least 0.3% lower than in full load. 3. If the CO2 content must be changed: Unscrew cover cap B. Turn adjustment screw A in small increments (Torx 40) until CO2 content is at the indicated level: Turning clockwise → CO2 content increases, Turning counter-clockwise → CO2 content decreases. 4. Record measurement reading in record (on page 219). Check measurement readings again. Start up the upper and lower heating output via the burner control unit. If the values do not correspond with the permissible CO2 contents as per the tables on page 78 and 79, the steps for the upper and lower heating output must be repeated. 5. Press buttons S E and D simultaneously for longer than 2 sec. Burner changes to operating mode. 80 MBH 1500 8.3 +0.1/-0.2% 2000 8.5 +0.1/-0.2% 5776 774 - 05 Burner models Permissible CO2 content Natural gas Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Displaying Ionization Current IMPORTANT Ionization current must be queried via the burner control unit. An ionization current measurement with Testomatic Gas or a multimeter is not possible. 1. Press button S for approx. 2 sec., „ 2. Press button “ will blink. until “5” appears under Service. 3. Press button S. “5” will appear under Status. 4. Press button until “3” appears under Service. 5. Press button S. “3” will appear under Status and the ionization current in operation will be indicated under Service (i.e. 30 = 3,0 μA). 6. Put burners into operation with chimney sweep testswitch. 7. Take ionization current reading. IMPORTANT The ionization current must reach a minimum of 3 μA for approximately 2 to 3 sec. after opening of the combination gas valve and while in operation. 8. Record measurement reading in log. 9. Press button S approx. 2 sec, „ 10. Press button “ will blink. until “5” appears under Service. 11. Press button S. “5” will appear under Status. 12. Press button until “0” appears under Service. 13. Press button S. The operating status indicator appears again. Turning the System Off 1. Turn off main power switch or power supply voltage and ensure against being unintentionally switched on again. WARNING Power supply voltage is dangerous and may cause life-threatening injury. The system must be disconnected from the power supply before maintenance work is performed. 5776 774 - 05 2. Close central gas shut-off valve. 81 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Dismantling the Burner IMPORTANT Please observe chapter “Preparing for service work on the boiler and burner” on page 74. Detach upper burner section 1. Disconnect the burner gas line. 2. Disconnect the connector from the burner control unit. 3. Pull off the ignition electrode connectors. 1. Remove 2 screws on the ignition electrode block. Lift the electrode block upwards to remove. 82 5776 774 - 05 2. Remove 6 nuts. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Dismantling the Burner (Continued) Secure lifting mechanism chains at 3 points A on the frame of the upper burner section. 1. Lift upper burner section with lifting mechanism. 2. Swing upper burner section to the side. IMPORTANT A lifting mechanism is required to dismantle the burner. A lifting mechanism that can be mounted to the boiler is available as an accessory. This lifting mechanism is designed exclusively to lift out the burners. Installing the lifting device Refer to the Installation Instructions for lifting device. 1. Remove 8 nuts from the combustion chamber cover plate. 5776 774 - 05 2. Lift out mounting plate with burner tube. 83 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit 1. Disconnect KM-BUS connector avG. 2. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm). 3. Lift the display and programming unit and pull off the connector of the burner control unit connecting cable. Remove the display and programming unit. 4. Remove all connecting cables from the burner control unit. 5. Pull the coding card from the burner control unit. 6. Undo 4 mounting screws on the burner control unit. 7. Remove the burner control unit. 8. Install the new burner control unit in reverse order. 84 5776 774 - 05 9. For further steps, see chapter “Further assembly” on page 101. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Coding Card on Burner Control Unit 1. Disconnect KM-BUS connector avG. 2. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm). 3. Lift the display and programming unit and pull off the connector of the burner control unit connecting cable. Remove the display and programming unit. 4. Pull the coding card from the burner control unit. 5. Insert new coding card. 6. For further steps, see chapter “Further assembly” on page 101. Note: If fault code “F b7” is displayed, check the coding card. 5776 774 - 05 Refer to the Service Instructions. 85 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Display and Programming Unit of Burner Control Unit 1. Disconnect KM-BUS connector avG. 2. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm). 3. Lift the display and programming unit and pull off the connector of the burner control unit connecting cable. Remove the display and programming unit. 4. Install new display and programming unit in reverse order. 86 5776 774 - 05 5. For further steps, see chapter “Further assembly” on page 101. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Shutting Down the System 1. Close the gas shut-off valve. 2. Switch OFF the main circuit breaker or the power supply and safeguard against unauthorized reconnection. WARNING Mains voltage can be extremely dangerous. For maintenance work, isolate the system from the power supply. 3. Remove the boiler left side panels (see page 74). 5776 774 - 05 4. Disconnect power cable with plug 40 . Then disconnect the burner cables with plugs 3 A/ 3 B, 15 A/15 B, 41 , 53 and in addition to plug 145 from the burner control unit and pull out of the burner casing. 87 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking the 15A and 15B Secondary Boiler Temperature Sensors Resistance in k ohms Note: The sensor is located in each boiler section and the connecting plug is located at the burner control unit, for that boiler section. Checking the 3A and 3B boiler temperature sensor Note: The sensor is located on the boiler supply connection and the connecting plug is located at the burner control unit. Note: For sensor replacement see pages 90 and 91. Temperature Resistance in k ohms 3A sensor (NTC 10k) Temperature Resistance in k ohms 3B sensor (NTC 20k) 88 5776 774 - 05 Temperature Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Service 3A and 3B Boiler Temperature Sensor Description 3A sensor (NTC 10k) terminals 1 & 2 5776 774 - 05 3B sensor (NTC 20k) terminals 3 & 4 89 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler Secondary Temperature Sensor Note: The boiler secondary temperature sensor is located on the boiler section pressure vessel. 1. Remove spring clip from the sensor well and set aside. 2. Remove the boiler secondary temperature sensor from the sensor well. 3. Disconnect sensor cable plugs 15 A/15 B. 4. Connect new sensor to sensor cable plugs 15 A/15 B and install into the sensor well. 90 5776 774 - 05 5. Reinstall spring clip. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Service Boiler Water Temperature Sensor Note: The boiler water temperature sensor is located on the boiler section pressure vessel. 1. Remove spring clip from the sensor well and set aside. 2. Remove the flue gas temperature sensor from the sensor well. 3. Disconnect sensor cable plugs 3 A/ 3 B. 4. Connect new sensor to sensor cable plugs 3 A/ 3 B and install into the sensor well. 5776 774 - 05 5. Reinstall spring clip. 91 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Manual Reset Limits Temperature limit switch If the temperature at the probe exceeds the set limit, the snap-action switch is operated, the circuit is opened or closed and the snap-action switch is locked out mechanically. After the temperature has fallen below the limit temperature by about 14°F (8°C), the snap-action switch can be reset manually. Legend A Probe well B Supply water temperature limit switch C Flue gas temperature limit switch IMPORTANT 92 5776 774 - 05 The switches are preset fom the factory, do not adjust. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Gas Valve Note: The gas valve is installed horizontally, rotated 90°. 1. Undo screws and pull connectors from the gas valve and both gas pressure switches. 2. Pull the compensation line from the gas valve. 3. Undo nuts on the gas line flange. Remove the flange. 4. Undo nuts on the Venturi flange. Remove the flange. Assembly Assembly in reverse order Check for correct orientation when fitting. Replace the gaskets on the inlet and outlet sides. Secure the gas valve free from stress on the flange using screws. Torque: 13 lb.in (1.5 Nm) For further steps, see chapter “Further assembly” on page 101. Note: Never interchange the connecting cables of the two gas pressure switches (GDW 1 and GDW 2). WARNING Escaping gas leads to a risk of explosion. Check the fitting for gas tightness. CAUTION The use of leak detection spray can result in faulty operation. Leak detection spray must not come into contact with electrical contacts. Air Pressure Switch Compensation lines Replacement lines must be cut to length. See following table for required length. Line Burner model 1500/2000 MBH Length in. (mm) A a (6) B d (4) 6/9 (150/230) C d (4) 1e (35) 7 in. (mm) Burner model 1500/2000 MBH Length in. (mm) D d (4) 10f (270) E d (4) 15/17 (380/430) F d (4) 15/13c (380/350) G a (6) 13c (350) Line 5776 774 - 05 7 in. (mm) 7 (200) 93 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Air Pressure Switch (Continued) 1. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm) 2. Remove the display and programming unit from the burner control unit. 3. Pull connector aCA (LDW1) and connector aCAA (LDW2) from the plug-in strip on the burner control unit. 4. Pull compensation hose from connector. 5. Undo the mounting screw(s) on the air pressure switch. Remove the air pressure switch cover. Torque when installing: 9 lb.in (1 Nm). 6. Undo the base mounting screws and remove the base. 7. Install new air pressure switch in reverse order. Observe torque settings. Note: Attach the connection hose to the corresponding connector. 8. For further steps, see chapter “Further assembly” on page 101. Note: Set the new air pressure switch to exactly the same value as that of the replaced air pressure switch. Legend A Air pressure switch, fan (LDW1, compensation line on connector marked “-”) B Air pressure switch, combustion chamber (LDW2, compensation line on connector marked “+”) C Air pressure switch LDW2, for burner model 2000 MBH (Compensation line on connector marked “+”) Air pressure switch settings Burner model 1500 MBH 2000 MBH LDW1 mbar (“w.c.) 1 (0.4) 1 (0.4) LDW2 mbar (“w.c.) 9 (3.6) 12.5 (5.0)* All gas pressure switches are Dungs unless otherwise noted. * Equipped with a non adjustable Kromschroder valve. 94 5776 774 - 05 Only for Dungs gas pressure switches. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Ignition Unit 1. Pull the connecting cable from the ignition unit. 2. Pull the ignition cables from the ignition unit. 3. Undo the ignition unit mounting screws. Remove the ignition unit. 4. Install new ignition unit in reverse order. Torque for mounting screws: 13 lb.in (1.5 Nm). 5. For further steps, see chapter “Further assembly” on page 101. Ignition Cables 1. Pull the ignition cables from the ignition unit. 2. Pull the ignition connectors from the ignition electrodes. 3. Install new ignition cables in reverse order. 4. For further steps, see chapter “Further assembly” on page 101. Fan 1. Disconnect both connectors from the fan. 2. Remove 6 nuts on the Venturi pipe. Remove the Venturi pipe with the fitted gas valve. Torque when installing: 4.5 lb.ft (6 Nm). 3. Undo the hexagon nuts from the 4 studs. 4. Remove the fan, noting how the gasket is positioned. 5. Installation in reverse order. Note: Fit gasket in the correct position. 5776 774 - 05 6. For further steps, see chapter “Further assembly” on page 101. 95 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Rotary Damper and Servomotor 1. Pull the connector from the servomotor. 2. Undo 4 screws from the retaining bracket of the rotary damper. Torque when installing: 13 lb.in (1.5 Nm). Remove rotary damper together with the retaining bracket. 3. Undo 2 screws on the servomotor axis. Torque when installing: 3 lb.ft (4 Nm). 4. Remove the servomotor. 5. Release the articulated rod on the rotary damper with an open-ended wrench size 7. 6. Install new rotary damper, air pressure switch and servomotor in reverse order. IMPORTANT An incompletely opened rotary damper can cause malfunctions or indicate incorrect adjustment of the servomotor. The rotary damper must be fully open when the burner is off and during operation. If necessary, adjust it via the articulated rod. See service instructions for servomotor settings. 96 5776 774 - 05 7. For further steps, see chapter “Further assembly” on page 101. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking and Cleaning the Burner Tube WARNING Gas leakage can lead to risk of explosion. Close gas shut-off valve. WARNING Contact with hot surfaces can lead to burn injuries. Undertake work on the burner only when the system is cold. 1. Bend hanger up on the support of the refractory. 2. Remove refractory. 3. Remove screws from the burner tube flange. Detach burner tube. 4. Check metal mesh of burner tube for damages. 5. Replace all gaskets. Reassemble burner tube and burner in reverse order. Torque: 7.5 lb.ft (10 Nm). CAUTION Scratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber. CAUTION Contamination of the burner tube can lead to malfunctions. When exchanging the burner tube, ensure that no fibres from the heat insulation block stick to the burner tube. CAUTION 5776 774 - 05 Improperly executed exchange of the burner tube can lead to contamination of the combustion chamber. Ensure that the combustion chamber is maintained free of insulation fibres. 97 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking the Ignition Electrodes and Ionization Electrode Electrodes 1. The electrode block can be tested or dismounted once the burner plate has been dismounted. 2. Check ignition electrodes and ionization electrode for damages and that they are situated at the correct distance from the burner tube. Replace electrodes if necessary. 3. Install the electrode block in reverse order. Fit new gaskets. Torque: 3 lb.ft (4 Nm). Cleaning the Burners IMPORTANT Close the central gas shut-off valve for all dismantlement work on the burners. For dismantling the burners see from page 82. 1. Disconnect Venturi mixing tube D from fan E. 2. Detach Venturi mixing tube D with combination gas valve A and gas connector pipe B and if applicable, detach connector pipes. 3. Detach connector pipes a-Ö and a-ÖA from fan E and dismantle fan. 4. Clean fan housing and fan impeller with compressed air. 5. If necessary, vacuum clean burner tube F from inside and out. Legend A Combination gas valve B Gas connector pipe C Fitting at gas connector pipe D Venturi-mixing tube E Fan F Flame tube 6. Reassemble in reverse order. IMPORTANT Ensure correct positioning of gasket between fan housing and burner plate. Replace gasket if damaged. WARNING 98 5776 774 - 05 Risk of explosion due to gas leakage. Check for gas leakage at screws and the gasket between the fan housing and the burner plate. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Service Cleaning the Combustion Chamber and Heating Surfaces CAUTION Scratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber. CAUTION Scratches on parts that come into contact with flue gas can lead to corrosion. Use only plastic brushes; do not use metal brushes or sharp objects. Cleaning the combustion chamber and heating surfaces Thoroughly clean the combustion chamber and heating surfaces with a water jet. Note: Scratches on parts that are in contact with flue gas can lead to corrosion. Only use plastic brushes, not wire brushes nor sharp objects. For normal cleaning, flush the heating surfaces thoroughly with a water jet. You may use cleaning agents if you notice stubborn residues, surface discoloration or soot deposits. For this, observe the following: ■ Only use solvent-free cleaning agents. Ensure that no cleaning agent gets between the boiler body and the thermal insulation. Note: The cleaning agent must not contain hydrocarbonbased solvents or potassium. Follow the cleaning agents instructions. ■ Remove deposits of combustion by-products with alkaline agents. ■ Remove coatings and surface discoloration (yellowish brown) with phosphoric acid-based Antox 75 E Plus or citric acid-based CitriSurf 3050 or CitriSurf 77 by Stellar Solutions Inc. ■ Rinse thoroughly with water. Checking gaskets and thermal insulation parts 1. Check gaskets and the sealing rope for damage. 2. Check the thermal insulation components for possible damage. 5776 774 - 05 3. Replace any damaged parts. 99 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking all Connections Around the Heating Water for Leakage WARNING Working on pressure loaded parts can be dangerous. Connections around the heating water should only be opened if the boiler is unpressurized. CAUTION Under-pressure in the boiler can lead to material damages. Only empty boiler with open ventilation with a suction pump. IMPORTANT Ensure that connections for control equipment and minimum pressure monitor (low-water indicator) are also leakage-free. Cleaning of Condensate Drainage System Note: Clean the inside of the condensate drain system at least annually. Checking the condensate drain and the neutralizing system (if installed) Add water to the flue gas collector through the inspection port E. Note: The water must flow from the condensate drain without back pressure. If necessary, clean the condensate drain again. IMPORTANT If the condensate does not drain freely, the condensate will accumulate in the bottom part of the boiler, resulting in burner shut-down (fault message). Check neutralization unit (if installed) 1. Pull drain or cleaning hose D off. 1. Check the pH value of the condensate with a pH measuring strip (field supplied). If the pH value is less than 6.5, replace granulate. 2. Clean the inside of the condensate drain system (hose, pipe). 2. If contaminated - rinse the neutralization unit with tap water. 3. Clean the neutralizing system (if installed) in accordance with the manufacturer‘s instructions. 3. Add granulate as marked. Note: You can obtain the neutralizing granulate from Viessmann. 4. Release and flush lower part C of siphon B. 5. Fill lower part C of siphon B with water and reassemble. 6. Install hose A of the neutralizing system to the siphon. 100 IMPORTANT The granulate is consumed as it neutralizes the condensate. The red marking indicates the minimum filling level. See Neutralization Unit ”Installation Instructions”. 5776 774 - 05 See Neutralization System Operating Instructions. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Further Assembly and Commissioning WARNING Escaping gas leads to a risk of explosion. Check the fitting for gas tightness. 1. Position the burner tile with burner mesh assembly on the 8 studs on the boiler section. Tighten nuts with a torque of 29.5 lb.ft 40 Nm). 2. Push on the electrode connectors. 3. Insert connectors at the plug-in panel and at the burner control unit; insert mains plug fÖ last. 4. Fit the gas connection pipe. Note: The use of leak detection spray can result in faulty operation. Leak detection spray must not come into contact with electrical contacts. 5. Start the burner and carry out a function test. Vitocrossal CA3 installation and service instructions. 6. Install the boiler jacket. Checking for Flue Gas Leakage CAUTION Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury or loss of life. Flue gases may contain deadly carbon monoxide. Check flue gas collector and boiler body for leakage. IMPORTANT Gaskets can be checked with a dew point hygrometer at full load operation. Detach thermal insulation parts if necessary. Traces of condensed water on the exterior of the glue gas collector or on the thermal insulation parts also indicate leakages. Automatic Leakage Test for Valves of the Combination Gas Valve WARNING 5776 774 - 05 Risk of explosion due to gas leakage. Check for gas leakage at the gauge connections. The burner control unit triggers an automatic leakage check of both valves at burner start-up. If valves are leak-free the burner shifts into normal operating mode and the burner ignites. If the first valve leaks, the error code “F E1” will appear in the burner control unit display, if the second valve leaks, “F E2” will appear. In both cases, the combination gas valve should be replaced. 101 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking On-site Gas Connections for Leakage WARNING Risk of explosion due to gas leakage. Check for gas leakage at the gauge connections. CAUTION Use of leak detection spray can lead to operational malfunctioning. Leak detection spray must not come into contact with electrical contacts. 1. Insert and tighten new gaskets at all detached on-site connections. 2. Open gas shut-off valve. 3. Check sealing points at input side of the combination gas valve for leakage. 4. Put boiler into operation (see page 68). 5. Check output-side sealing points of combination gas valve, sealing points between fan and burner plate and sealing points between fan and Venturi-tube for leakage. Taking Final Measurement Reading 1. Take CO2 measurement reading after each burner dismantling in accordance with the items beginning from pages 79 and 80. 2. Record measurement readings in record on page 219. Checking the Water Conditions Water Quality Hard water conditions (i.e. calcium carbonate) must be avoided as it will cause deposits to accumulate on the heat exchanger surfaces. If in any doubt about the water quality, please have a proper water analysis done. Check with regional chemical suppliers for boiler water treatment or with Viessmann Manufacturing Company Inc. directly. Total output (MBH) Total Hardness (ppm as CaCO3) > 1 Total 680 200 > 680 to 2050 150 > 2050 2 The pH value of the heating water should be between 8.2 and 9.5 102 The standard values assume the following: The total volume of fill and top-up water during its service life will not exceed three times the water content of the heating system. The specific system volume is less than 1.5 USG/MBH (20 L/kW) heating output. In multiboiler systems, apply the output of the smallest boiler. Soften the fill and top-up water in heating systems operating under the following conditions: The total of alkaline earths in the fill and top-up water exceeds the standard value. Higher fill and top-up water volumes are expected. The specific system volume is higher than 1.5 USG/ MBH (20 L/kW) heating output. In multiboiler systems, apply the output of the smallest boiler. 5776 774 - 05 The lifetime of the entire heating system is influenced by the water quality. A water treatment system will protect against damages caused by corrosion and lime formation. Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking Expansion Tank and System Pressure Check proper expansion tank and system pressures See expansion tank manufacturer’s instructions. IMPORTANT The diaphragm expansion tank must be able to hold the heating water expansion volume inside the boiler, and must be properly sized for the system. CAUTION Damage on boiler or other system components may result if these recommendations are not followed. CAUTION Carry out all check in accordance with the expansion tank manufacturer’s instructions. Limit pressure fluctuations to the lowest possible differential. Cyclical pressure fluctuations and greater pressure differentials indicate a system fault. Immediately remedy such faults, otherwise other heating system components may become faulty. This diaphragm expansion vessel reduces the frequency and severity of pressure fluctuations; the service life of the circulating pump is improved and therefore the operational reliability and service life of system components increased. IMPORTANT Carry out this test on a cold system. 1. Drain system or close cap valve on the diaphragm expansion tank and reduce the pressure until the pressure gauge indicates “0”. 2. 60°F (15.5°C) water fill pressure must equal diaphragm expansion tank pressure. Mixing Valve Movement and Leak Check 1. Remove motor lever from mixing valve handle. 2. Check mixing valve for ease of movement. 3. Check leak tightness of mixing valve. Replace O-ring if there is a leakage. 5776 774 - 05 4. Engage motor lever. 103 Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking Air Intake in the Installation Room (visual check) Check filter and air intake during room-air-dependent operation. Check the air intake outside the installation room as well during room-air-dependent operation. Instructing the Operator of the System The system manufacturer must hand over the operating instructions to the system operator and instruct him in its operation. This includes all accessories that have been installed as components, such as remote controls. The system manufacturer must also provide instruction regarding maintenance work. Operating and Service Documents 1. Complete customer information file and separate: Hand over segment for system operator to system operator. Retain segment for heating contractor in files. 104 5776 774 - 05 2. Assemble all parts lists, operating and service instructions in a file and deliver to the system operator. After installation, the installation instructions will no longer be required and do not need to be retained. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Coding levels Calling up Coding Levels H The coding indicators are preset by the configuration of the heating system. H Coding is split into the following groups: – “General” – “Burner control unit” – “DHW” – “Solar” – “Heating circuit 1/2/3” – “Boiler” – “Cascade” – “All coding” In this group, all coding in the coding levels is listed in ascending order (except the coding in the “Solar” group). 6. Select group. 7. Select coding. 8. “Edit” for the required value in line with the following 9. tables. Display for coding levels H Heating systems with one heating circuit without mixing valve and one or two heating circuits with mixing valve: In the following, the heating circuit without mixing valve is designated “Heating circuit 1” and the heating circuits with mixing valve as “Heating circuit 2” or “Heating circuit 3”. H The selected designation appears if the heating circuits have been designated individually. From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “System configuration” 5. “Coding level 1” or “Coding level 2”: Enter “viexpert” password. Legend A Coding B Number of coding C Value of coding D Coding description Resetting Coding to their Factory Set Condition 5776 774 - 05 From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “System coding” 5. “Coding level 1” or “Coding level 2”: Enter “viexpert” password. 6. “Reset coding” 105 Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group Coding Coding in the factory set condition System design 00:1 System version 1: One heating circuit without mixing valve A1 (heating circuit 1), without DHW heating Possible change 00:2 to 00:10 For system schemes, see the following table: Value address 00: Description ... 2 One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating; recognized automatically. 3 One heating circuit with mixing valve M2 (heating circuit 2), without DHW heating. 4 One heating circuit with mixing valve (heating circuit 2), with DHW heating 5 One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), without DHW heating; recognized automatically. 6 One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), with DHW heating; recognized automatically. 7 Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating. 8 Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating. 9 One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating; recognized automatically. 10 One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating; recognized automatically. LON participant no. 77:1 LON Participant number Boiler section 1 set to 1, boiler section 2/boiler section 3 set to 2 or 3. Possible change 40:5 to 40:199 Adjustable from 5 to 199 sec. 77:1 to 77:99 Adjustable from 1 to 99: 1 to 8 = Boiler and heating circuit control 10 - 96 = Vitotronic 200-H 97 = Vitogate 300 98 = Vitogate 99 = Vitocom 7F:0 Apartment building Separate adjustment of holiday program and time program for DHW heating possible. IMPORTANT If coding is to be set to the factory set condition, the participant number must be reset. “Detached house/apartment building” 7f:1 Detached house 106 5776 774 - 05 Coding in the factory set condition Servomotor runtime 40:... Actuator runtime at plug gSA1. Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition Possible change “Automatic summer/wintertime changeover” 81:1 Automatic summer/wintertime changeover. 81:0 Manual summer/wintertime changeover 81:2 Do not adjust! 81:3 With LON communication module: The control unit receives the time. 82:1 to 82:12 January to December 83:1 to 83:5 Week 1 to week 5 of the selected month. 83:6 Last week - 1 week 83:7 Last week - 2 weeks 83:8 Last week - 3 weeks 83:9 Last week - 4 weeks 83:10 to 83:14 Special function 84:1 to 84:7 Monday to Sunday. 85:1 to 85:12 January to December 86:1 to 86:5 Week 1 to week 5 of the selected month. 87:1 to 87:7 Monday to Sunday -- -- 9b:0 to 9b:127 Adjustable from 32 to 261°F (0 to 127°C) (limited by boiler specific coding). “Summer time starts: Month” 82:3 March “Summer time starts: Week of the selected month” 83:2 Week 2 of the selected month. “Summer time starts: Day of the selected week” 84:7 Last Sunday of the selected month. “Wintertime starts: Month” 85:11 November “Wintertime starts: Week of the selected month” 86:1 Week 1 of the selected month. “Wintertime starts: Day of the selected week” 87:7 Last Sunday of the selected month. “Operation enabled/blocked” 8f:0 Do not adjust! “Set supply temperature for external demand” 5776 774 - 05 9b:70 Set to 158°F (70°C) 107 Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Combustion Controller” Group Coding Coding in the factory set condition Possible change “Max operational output” 02:100 100% of rated heating output. 02:0 to 02:100 Adjustable from 0 to 100% (0% represents burner minimum firing rate). Natural gas 03:1 LPG - Do not adjust! LA: ≤ 1500 m 04:1 HA: > 1500 m 06:5 to 06:127 Adjustable from 41 to 261°F (5 to 127°C). 08:1 to 08:255 Adjustable from 1 to 255 Kmin 09:0 Minimum pause “Gas type” 03:0 “Altitude” 04:0 “Max boiler temperature” 06:95 Set to 203°F (95°C). IMPORTANT Supply temperature limit switch common supply, set to 99 °C (tolerance -6K). “Integral threshold value of controller” 08:30 Set to 30 Kmin. “Runtime optimization” 09:1 Integral method “Boiler” Group Coding in the factory set condition Possible change “Single boiler and multi boiler system” 01:2 Multi-boiler system with Viessmann-cascade 01:1 or LON-cascade. 01:3 Do not adjust! Do not adjust! “Consecutive boiler number in multi boiler systems” 07:1 Consecutive boiler number in multi boiler systems. Is not indicated for boiler section 1. Boiler section 2/boiler section 3 factory set. 07:2 to 07:8 Adjustable from 1 to 8 -- -- 21:1 to 21:100 The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h; 1 step 100 h. 23:1 to 23:24 Adjustable from 1 to 24 months. “Flue gas temperature sensor” 1f:0 Do not adjust! “Service interval” 21:0 No service interval (hours run) selected. 23:0 108 No interval for service. 5776 774 - 05 “Interval for service” Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Boiler” Group (continued) Coding in the factory set condition Possible change ”Service” display” 24:0 No “Service” display 24:1 “Service” is displayed (the address is automatically set and must be manually reset after a service has been carried out). “Cascade” Group Coding Coding in the factory set condition Possible change “Number of boilers connected to the cascade” 35:2 to 3 8 boilers Factory set conditions: CA3 3.5/4.0: 2 CA3 5.0/5.0: 3 35:1 to 35:8 1 to 8 boilers 36:1 to 36:127 Adjustable from 32 to 261°F (0 to 127°C) (only when operating with standard room temperature). 37:20 to 37:127 Adjustable from 68 to 261°F (20 to 127°C). 38:1 Boiler section 1 changeover: Every first day of the month, the boiler with the shortest number of hours run by its burner becomes the boiler section 1. 38:2 to 38:200 Boiler section 1 changeover after 200 to 20,000 hours run 1 step 100 hours run. 39:1 to 39:3 Permanent boiler section 1 is boiler 1, 2 or 3. 3a:1 to 3a:3 Permanent last boiler section 2/boiler section 3 is boiler 1, 2 or 3. “Minimum system supply temperature limit” 36:0 Electronic minimum system supply temperature limit set to 32°F (0°C). “Maximum system supply temperature limit” 37:80 Electronic maximum system supply temperature limit set to 176°F (80°C). Note: Value must be lower than the lowest value of coding “06” in the “Combustion controller” group of every control unit. “Boiler section 1 or boiler sequence changeover” 38:0 No boiler section 1 or boiler sequence changeover (see function description in chapter “Cascade control”). “Permanent boiler section 1” 39:0 No permanent boiler section 1. “Permanent last boiler” 5776 774 - 05 3a:0 No permanent last boiler. 109 Coding level 1 “Cascade” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Coding in the factory set condition Possible change “Type of control” 3b:1 Standalone parallel boiler circuit: With supply temperature sensor (see page 181). 3b:0 Standalone parallel boiler circuit: Without supply temperature sensor (see page 182). 3b:2 Standalone serial boiler circuit: Without supply temperature sensor (see page 182). 3b:3 Standalone serial boiler circuit: With supply temperature sensor (see page 182). 3b:4 Sequential control method with supply temperature sensor (see page 182). 3c:1 Conventional boiler strategy 1 (see page 184). 3c:2 Conventional boiler strategy 2 (see page 184). 3d:0 No output statement “Control strategy” 3c:0 Condensing strategy (see page 183). “Output statement” 3d:1 Output statement for condensing strategy and conventional boiler strategy 1. Note: Control only in accordance with conventional boiler strategy 2. “ECO threshold boiler 1” 41:31 No ECO threshold boiler 1. 41:−30 to 41:+30 Adjustable from -22 to 86°F (−30 to +30°C). 42:−30 to 42:+30 Adjustable from -22 to 86°F (−30 to +30°C). 43:−30 to 43:+30 Adjustable from -22 to 86°F (−30 to +30°C). 44:−30 to 44:+30 Adjustable from -22 to 86°F (−30 to +30°C). 45:1 to 45:255 Adjustable from 1 to 255 K x minute. “ECO threshold boiler 2” 42:31 No ECO threshold boiler 2. “ECO threshold boiler 3” 43:31 No ECO threshold boiler 3. “ECO threshold boiler 4” 44:31 No ECO threshold boiler 4. “Start integral threshold” 110 Set to 60 K x minute. Note: A boiler or burner stage will shut down if this value is exceeded. 5776 774 - 05 45:60 Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Cascade” Group (continued) Coding in the factory set condition Possible change “Stop integral threshold” 46:40 Set to 40 K x minute. 46:1 to 46:255 Adjustable from 1 to 255 K x minute. Note: A boiler or burner stage will shut down if this value is exceeded. 47:2 to 47:30 Adjustable from 2 to 30 K. 65:−30 to 65:+30 Adjustable from -22 to 86°F (−30 to +30°C). 6F:−30 to 6F:+30 Adjustable from -22 to 86°F (−30 to +30°C). 74:−30 to 74:+30 Adjustable from -22 to 86°F (−30 to +30°C). 7d:−30 to 7d:+30 Adjustable from -22 to 86°F (−30 to +30°C). “Stop differential” 47:15 Set to 15 K. Note: One boiler or one burner stage will be shut down if the actual supply temperature exceeds the set supply temperature by this value. “ECO threshold boiler 5” 65:31 No ECO threshold boiler 5. “ECO threshold boiler 6” 6F:31 No ECO threshold boiler 6. “ECO threshold boiler 7” 74:31 No ECO threshold boiler 7. “ECO threshold boiler 8” 7d:31 No ECO threshold boiler 8. “DHW” Group Coding Coding in the factory set condition “Storage tank heating, hysteresis” Possible change 55:0 55:1 Tank heating hysteresis ± 2.5 K. 55:2 5776 774 - 05 55:3 Adaptive storage tank heating enabled (see page 191). Storage tank temperature control with 2 temperature sensors (see page 191). Storage tank temperature control, storage tank loading system (see page 191). 111 Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “DHW” Group (continued) Coding in the factory set condition “For solar DHW heating: DHW temperature target” 67:40 DHW setpoint temperature 104°F (40°C). Reheating is suppressed above the selected set temperature (DHW heating blocked by the boiler). “DHW recirculation pump” 73:0 ON according to time program Possible change 67:0 to 67:95 Adjustable from 32 to 203°F (0 to 95°C) (limited by boiler-specific coding). 73:1 to 73:6 73:7 “ON” from once per hour for 5 min up to 6 times per hour for 5 min during the time program. Permanently ON “Solar” Group Note: The “Solar” group is only displayed if a solar control module, type SM1, is connected. Coding Possible change 02:1 02:2 “Maximum storage tank temperature” 08:60 DHW setpoint temperature (maximum tank temperature) 140°F (60°C). 08:10 to 08:90 “Stagnation time reduction” 0a:5 Temperature differential for stagnation time 0a:0 reduction (reduction in the speed of the solar circuit pump to protect system components 0a:1 and heat transfer medium) 5 K. to 0a:40 “Solar circuit flow rate” 0f:70 Solar circuit flow rate at maximum pump 0f:1 speed 1.8 USG/min (7 L/min). to 0f:255 112 Variable speed solar circuit pump with wave packet control. Solar circuit pump speed controlled with PWM control. Adjustable from 50 to 194°F (10 to 90°C). Stagnation time reduction disabled. Temperature differential adjustable from 1 to 40 K. Adjustable from 0.02 to 6.7 USG/min (0.1 to 25.5 L/min), 1 step 0.02 USG/min (0.1 L/min). 5776 774 - 05 Coding in the factory set condition “Solar circuit pump speed control” 02:0 Solar circuit pump is not speed controlled. Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Solar” Group (continued) Coding in the factory set condition “Extended control function” 20:0 No extended control function enabled. Possible change 20:1 20:2 20:3 20:4 20:5 20:6 20:7 20:8 20:9 Additional function for DHW heating. Differential temperature control 2. Differential temperature control 2 and auxiliary function. Differential temperature control 2 for central heating backup. Thermostat function Thermostat function and auxiliary function. Solar heating via external heat exchanger without additional temperature sensor. Solar heating via external heat exchanger with additional temperature sensor. Solar heating of two DHW storage tanks [Solar heating of two DHW tanks]. “Heating Circuit ...” Group Coding Coding in the factory set condition “Storage tank priority” a2:2 Tank priority control for heating circuit pump and mixing valve. Possible change a2:0 a2:1 a2:3 to a2:15 “Heating circuit pump logic function (economy control)” a5:5 With heating circuit pump logic function (economy control): heating circuit pump OFF when the outdoor temperature (OT) is 1 K higher than the set room temperature (RTset) OT > RTset +1 K. a5:0 a5:1 to a5:15 Without storage tank priority applicable to heating circuit pump and mixing valve. Storage tank priority only applicable to mixing valve. Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat. Without heating circuit pump logic function. With heating circuit pump logic function: Heating circuit pump OFF, see the following table. 5776 774 - 05 Coding address With heating circuit pump logic function: a5:... Heating circ pump OFF 1 OT > RTset + 5 K 2 OT > RTset + 4 K 3 OT > RTset + 3 K 4 OT > RTset + 2 K 5 OT > RTset + 1 K 6 OT > RTset 7 OT > RTset – 1 K to 15 OT > RTset – 9 K 113 Coding level 1 “Heating Circuit ...” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Coding in the factory set condition “Extended economy mode” a6:36 Extended economy mode disabled. Possible change a6:5 to a6:35 “Mixing valve economy function” a7:0 Only for heating circuits with mixing a7:1 valve: Without mixing valve economy function. Extended economy mode enabled, i.e. the burner and heating circuit pump will stop and the mixing valve will be closed at a variable value, adjustable between 41 to 95°F (5 and 35°C) plus 2°F (1°C). The base value is the adjusted outdoor temperature. This value is based on the actual outdoor temperature and a time constant, which takes the cooling down of an average building into consideration. With mixing valve economy function: Heating circuit pump also OFF: H Mixing valve tries closing for more than 20 min. Heating circuit pump ON: H Mixing valve in control mode. “Pump idle time” a9:0 Without pump idle time. a9:7 H If there is a risk of frost With pump idle time (heating circuit pump turned off). Function description page 187 Note: The maximum idle time is 10 h. “Room temperature hook-up” b0:0 With remote control:*1 Heating mode/reduced mode: Weather-compensated a9:1 to a9:15 Pump idle time adjustable from 1 to 15. 1: Short idle time 15: Long idle time b0:1 Heating mode: Weather-compensated Reduced mode: with room temperature hook-up Heating mode: with room temperature hook-up Reduced mode: Weather-compensated b0:2 b0:3 “Room temperature-dependent heating circuit pump logic function” b5:0 With remote control: b5:1 No room temperature-dependent heating to circuit pump logic function. b5:8 Heating mode/reduced mode: with room temperature hook-up. For heating circuit pump logic function, see the following table: 114 5776 774 - 05 *1 Only change the coding for the heating circuit without mixing valve A1 for boilers without lower temperature limit or for heating circuits with mixing valve if a remote control is connected to them. Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group (continued) Coding address With heating circuit pump logic function: b5:... Heating circ pump OFF 1 RTactual > RTset + 5 K 2 RTactual > RTset + 4 K 3 RTactual > RTset + 3 K 4 RTactual > RTset + 2 K 5 RTactual > RTset + 1 K 6 RTactual > RTset 7 RTactual > RTset – 1 K 8 RTactual > RTset – 2 K Coding in the factory set condition “Minimum supply temperature limit” c5:20 Electronic supply temperature minimum limit 68°F (20°C) (only for operation with standard room temperature). “Maximum supply temperature limit” c6:75 Electronic maximum supply temperature limit set to 167°F (75°C). Heating circuit pump on RTactual < RTset + 4 K RTactual < RTset + 3 K RTactual < RTset + 2 K RTactual < RTset + 1 K RTactual < RTset RTactual < RTset – 1 K RTactual < RTset – 2 K RTactual < RTset – 3 K Possible change c5:1 to c5:127 Adjustable from 34 to 261°F (1 to 127°C) (limited by boiler specific coding). c6:10 to c6:127 Adjustable from 50 to 261°F (10 to 127°C) (limited by boiler specific coding). d5:1 Changeover to “Constant operation with standard room temperature”. d8:1 Operating program changeover via input DE1. d8:2 Operating program changeover via input DE2. d8:3 Operating program changeover via input DE3. “External operating program changeover” d5:0 With external operating program changeover (observe setting of coding “5d”, “5e”, “5f” and “91” in the “General” group). Changeover “Constant central heating with reduced room temperature” or “Standby mode” (subject to set reduced room temperature). “EA1 extension: Operating program changeover” d8:0 No operating program changeover. “Slab curing” 5776 774 - 05 f1:0 Slab curing function not active. Do not adjust! 115 Coding level 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Time limit for comfort mode” f2:8 Time limit for comfort mode or external operating program changeover via push button: 8 h. f2:0 f2:1 Note: Observe setting of coding “5d”, to “5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” f2:12 group. No time limit Time limit adjustable from 1 to 12 h. “Temperature limit for terminating reduced mode” f8:–5 Temperature limit for terminating reduced mode 25°F (–5°C), see example on page 189. Observe coding “a3”. f8:+10 to f8:–60 Adjustable from 50 to -76°F (+10 to –60°C). f8:–61 Function disabled “Temperature limit for raising the reduced room temperature target” f9:–14 Temperature limit for raising the reduced room temperature target 7°F (–14°C), see example on page 189. f9:+10 to f9:–60 Adjustable from 50 to -76°F (+10 to –60°C). “Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature” fa:20 Raising the set boiler water or supply fa:0 temperature when changing from operation to with reduced room temperature to fa:50 operation with standard room temperature by 20%. See example on page 189. Adjustable from 0 to 50%. “Duration for raising the set boiler water or supply temperature” 116 Duration for raising the set supply temperature (see coding “fa”) 60 min. See example on page 189. fb:0 to fb:300 Adjustable from 0 to 300 min. 5776 774 - 05 fb:60 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group Coding Coding in the factory set condition System design 00:1 System version 1: One heating circuit without mixing valve A1 (heating circuit 1), without DHW heating. Value address 00: ... 2 Possible change 00:2 to 00:10 For system schemes, see the following table: Description One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating; recognized automatically. 3 One heating circuit with mixing valve M2 (heating circuit 2), without DHW heating. 4 One heating circuit with mixing valve (heating circuit 2), with DHW heating. 5 One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), without DHW heating; recognized automatically. 6 One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), with DHW heating; recognized automatically. 7 Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating. 8 Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating. 9 One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating; recognized automatically. 10 One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating; recognized automatically. Coding in the factory set condition Possible change “With EA1 extension: DHW recirculation pump runtime for brief operation” 12:5 DHW recirculation pump runtime for 12:1 Adjustable from 1 to 60 min. brief operation: 5 min. to 12:60 “With EA1 extension: Temperature demand” 1e: No factory No factory setting. 1E:0 Analog input 0-10 V: Temperature setting demand from 0 to 100 °C: 1 V 0 °C 10 100 °C 5776 774 - 05 2f:0 Do not adjust! “AM1 extension” 32:0 Without AM1 extension “Function output A2 at AM1 extension” 33:1 Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1). 1E:1 Adjustable from 86 to 248°F (30 to 120°C): 1V 86°F (30°C) 10V 248°F (120°C) 32:1 With AM1 extension 33:0 33:2 33:3 DHW recirculation pump DHW loading pump Circulation pump neutralizing system or flue gas/water-heat exchanger. 117 Coding level 2 “General” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Coding in the factory set condition “Function output A1 at AM1 extension” 34:0 DHW recirculation pump. Possible change 34:1 34:2 34:3 Heating circuit pump without mixing valve A1 (Heating circuit 1). Tank loading pump Circulation pump neutralizing system or flue gas/water-heat exchanger. “Servomotor runtime” 40:5 to 40:199 Adjustable from 5 to 199 sec. “Sensor 17A” 4a:0 Do not adjust! “Sensor 17B” -- -- 4b:0 4b:1 Sensor aJB installed (e.g. temperature sensor T2); automatic recognition. Servomotor runtime at plug gSA1 125 sec No sensor aJB installed. “Connection at plug 20A1” 4c:0 Connection on plug sÖA1: Heating circuit pump “Connection at plug 29” 4d:1 Connection at plug sL: Shunt pump. “Connection at plug 52A1” 4e:0 Motor isolation valve. 4c:1 Primary pump, tank loading system. 4c:2 Thermal control switch contact . 4d:0 4d:2 4d:3 Distribution pump Boiler pump Boiler pump with isolation valve function. 4e:1 Motor for 3-way mixing valve for return temperature control. Do not adjust! 4e:1 to 4e:3 “Delay off time, shunt or distribution pump” 4f:5 Delay off time distribution pump 5 min. 4f:0 4f:1 to 4f:60 “Supply temperature sensor for hydraulic low loss header” 52:0 Do not adjust! “Solar thermal system” 54:0 Without solar thermal system. “EA1 extension” 5b:0 Without EA1 extension. 118 54:1 to 54:3 54:4 5b:1 No pump delay off. Adjustable from 1 to 60 min. Do not adjust! With solar control module, type SM1, with auxiliary function, e.g. central heating backup; automatic recognition. With EA1 extension; automatic recognition. 5776 774 - 05 40:125 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition Possible change “Function output 157 at EA1 extension” 5c:0 Function output aBJ at EA1 extension: Central fault message 5c:1 Feed pump 5c:2 No function 5c:3 Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1), switched to low speed (reduced mode). 5c:4 Heating circuit pump, heating circuit with mixing valve M2 (heating circuit 2), switched to low speed (reduced mode). 5c:5 Heating circuit pump, heating circuit with mixing valve M3 (heating circuit 3), switched to low speed (reduced mode). 5d:1 Operating program changeover 5d:2 External demand with minimum set supply temperature. Set value adjustment at coding “9b” in the “General” group. 5d:3 External blocking 5d:4 External blocking with fault message. 5d:5 Fault message input. 5d:6 Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group. 5e:1 Operating program changeover 5e:2 External demand with minimum set supply temperature Set value adjustment at coding “9b” in the “General” group. “Function input DE1 at EA1 extension” 5d:0 No function “Function input DE2 at EA1 extension” 5776 774 - 05 5e:0 No function 5e:3 External blocking 5e:4 External blocking with fault message. 5e:5 Fault message input 5e:6 Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group. 119 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition Possible change “Function input DE3 at EA1 extension” No function 5f:1 Operating program changeover. 5f:2 External demand with minimum set supply temperature Set value adjustment at coding “9b” in the “General” group. 5f:3 External blocking 5f:4 External blocking with fault message. 5f:5 Fault message input 5f:6 Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group. “Shutdown delay neutralization system output 1 AM1” 6c:0 Delay off time circulation pump 6c:1 neutralizing system: None to 6c:255 “Shutdown delay neutralization system output 2 AM1” 6d:0 Delay off time circulation pump 6d:1 neutralizing system: None to 6d:255 “Display correction for outdoor temperature” 6e:50 No display correction for outdoor 6e:0 temperature. to 6e:49 6e:51 to 6e:99 “LON communication module” 76:1 With LON communication module; 76:0 automatic recognition. “LON participant number” 77:1 LON participant number 77:2 Boiler section 1 set to 1, boiler sec- to tion 2/boiler section 3 set to 2 or 3. 77:99 IMPORTANT If coding is to be set to the factory set condition, the participant number must be reset. “LON communication” 78:1 LON communication enabled 120 78:0 Adjustable from 1 to 255 sec Adjustable from 1 to 255 sec Display to Display Display to Display correction –5 K correction –0.1 K correction +0.1 K correction +4.9 K Without LON communication module. Adjustable from 1 to 99: 1 to 8 = Boiler and heating circuit control unit 10 - 96 = Vitotronic 200-H 97 = Vitogate 300 98 = Vitogate 99 = Vitocom LON communication disabled 5776 774 - 05 5f:0 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition “With LON communication module” 79:1 Control unit is fault manager. Possible change 79:0 Control unit is not fault manager IMPORTANT Must be set for boiler section 2/boiler section 3, see page 72. “Central control of heating circuits” 7a:0 Without central control of heating circuits. 7a:1 7a:2 7a:3 “LON communication module: Time” 7b:1 Control unit transmits the time. 7b:0 With central control Heating circuit without mixing valve A1 (heating circuit 1). Heating circuit with mixing valve M2 (heating circuit 2). Heating circuit with mixing valve M3 (heating circuit 3). No time transmission IMPORTANT Must be set for boiler section 2/boiler section 3, see page 72. “Detached house/apartment building” 7f:1 Detached house “Fault message” 80:6 A fault message is issued if a fault occurs for at least 30 sec. “Automatic summer/wintertime changeover” 81:1 Automatic summer/wintertime changeover. 5776 774 - 05 “Summer time starts: Month” 82:3 March 7F:0 Apartment building Separate adjustment of holiday program and time program for DHW heating possible. 80:0 80:2 to 80:199 Immediate fault message. Adjustable from 10 to 995 sec, 1 step 5 sec. 81:0 81:2 81:3 Manual summer/wintertime changeover Do not adjust! With LON communication module: The control unit receives the time. 82:1 to 82:12 January to December 121 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) “Summer time starts: Day of the selected week” 84:7 Last Sunday of the selected month. “Wintertime starts: Month” 85:11 November “Wintertime starts: Week of the selected month” 86:1 Week 1 of the selected month. “Wintertime starts: Day of the selected week” 87:7 Last Sunday of the selected month. Possible change 83:1 to 83:5 83:6 83:7 83:8 83:9 83:10 to 83:14 Last week – 1 week Last week – 2 week Last week – 3 week Last week – 4 week Special function 84:1 to 84:7 Monday to Sunday 85:1 to 85:12 January to December 86:1 to 86:5 Week 1 to week 5 of the selected month. 87:1 to 87:7 Monday to Sunday “Temperature displayed” 88:0 Temperature unit °C (Celsius). 88:1 “Test display conditions” 8a:175 Do not adjust! -“Identification KM bus combustion controller” 8b:1 ID exists 8b:0 “Operation enabled/blocked” 8f:0 Do not adjust! -“Time constant for calculating adjusted outdoor temperature” 90:36 Time constant 6 h. 90:1 to 90:199 122 Week 1 to week 5 of the selected month. Temperature unit °F (Fahrenheit) -ID does not exist -Fast (low values) or slow (high values) matching of the supply temperature, subject to the set value when the outdoor temperature changes 1 step 10 min. 5776 774 - 05 Coding in the factory set condition “Summer time starts: Week of the selected month” 83:2 Week 2 of the selected month. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Coding level 2 “General” Group (continued) Coding in the factory set condition Possible change “Connection at terminals 1 and 2 in plug 143” 91:0 Connection disabled (external operating program changeover). 91:1 Contact affects the following heating circuits: Heating circuit without mixing valve A1 (heating circuit 1). 91:2 Heating circuit with mixing valve M2 (heating circuit 2). 91:3 Heating circuit without mixing valve A1 (heating circuit 1) and heating circuit with mixing valve M2 (heating circuit 2). 91:4 Heating circuit with mixing valve M3 (heating circuit 3). 91:5 Heating circuit without mixing valve A1 (heating circuit 1) and heating circuit with mixing valve M3 (heating circuit 3). 91:6 Heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). 91:7 Heating circuit without mixing valve A1 (heating circuit 1) and heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). “Central fault message during emissions test function/service display” 93:0 Does not affect central fault. 93:1 Affects central fault message 95:1 With Vitocom 100 communication interface; automatic recognition. 96:0 Without PCB extension for heating circuits 2 and 3. 97:0 The outdoor temperature of the sensor connected to the control unit is only utilized internally. 97:1 The control unit receives the outdoor temperature from the Vitotronic 200-H. 98:1 to 98:5 Adjustable from 1 to 5 “Communication interface” 95:0 Without Vitocom 100 communication interface. “Extension for heating circuits 2 and 3 with mixing valve” 96:1 With PCB extension for heating circuits 2 and 3 Heating circuit is recognized automatically. “With LON communication module: Outdoor temperature” 97:2 The control unit sends the outdoor temperature to the Vitotronic 200-H. “Viessmann system number” 5776 774 - 05 98:1 Viessmann system number in conjunction with monitoring of several systems within one LON system with Vitocom 300. 123 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition Possible change “Connection at terminals 2 and 3 in plug 143” 99:0 Connection disabled 99:1 No function 99:2 External “mixing valve closed” Heating circuit with mixing valve M2 (heating circuit 2). 99:3 No function 99:4 External “mixing valve closed” Heating circuit with mixing valve M3 (heating circuit 3). 99:5 No function 99:6 External “mixing valve closed” Heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3. 99:7 No function 99:8 External blocking 99:9 No function 99:10 External blocking/External “mixing valve closed” Heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). 99:11 No function 99:12 External blocking/External “mixing valve closed” Heating circuit with mixing valve M3 (heating circuit 3). 99:13 No function 99:14 External blocking/External “mixing valve closed” Heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). 99:15 No function 9a:1 No function 9a:2 External “mixing valve open” Heating circuit with mixing valve M2 (heating circuit 2). 9a:3 No function 9a:4 External “mixing valve open” Heating circuit with mixing valve M3 (heating circuit 3) 9a:5 No function 9a:6 External “mixing valve open” Heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). 9a:7 No function 9b:0 to 9b:127 Adjustable from 32 to 261°F (0 to 127°C) (limited by boiler specific coding). “Connection at terminals 1 and 2 in plug 143 “ 9a:0 Connection disabled. 9b:70 124 Set to 158°F (70°C). 5776 774 - 05 “Set supply temperature for external demand” Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “General” Group (continued) Coding in the factory set condition Possible change “With LON communication module: Monitoring LON participants” 9c:20 Monitoring LON participants If there is no response from a participant after 20 min, the values specified inside the control unit are used. Only then will a fault message be issued. 9c:0 No monitoring. 9c:5 to 9c:60 Time adjustable from 5 to 60 min. 9f:0 to 9f:40 Adjustable from 0 to 40 K “Differential temperature” 9f:8 Differential temperature 8 K only in connection with heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). “Combustion Controller” Group Coding Coding in the factory set condition Possible change “Max operational output” 02:100 100% of rated heating output. 02:0 to 02:100 Adjustable from 0 to 100% (0% represents burner minimum firing rate). Natural gas 03:1 LPG - Do not adjust! LA: ≤ 1500 m 04:1 HA: > 1500 m 06:5 to 06:127 Adjustable from 41 to 261°F (5 to 127°C) 08:1 to 08:255 Adjustable from 1 to 255 Kmin. 09:0 Minimum pause. 0a:1 With “Gas type” 03:0 “Altitude” 04:0 “Max boiler temperature” 06:95 Set to 203°F (95°C) IMPORTANT Supply temperature switch common supply, set to 99 °C (tolerance -6K). “Integral threshold value of controller” 08:30 Set to 30 Kmin “Runtime optimization” 09:1 Integral method “Flue gas damper” 5776 774 - 05 0a:0 Without 125 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Boiler” Group Coding Coding in the factory set condition Possible change “Single boiler and multi boiler system” 01:2 Multi-boiler system with Viessmann-cascade or LON-cascade. 01:1 Do not adjust! 01:3 Do not adjust! 07:2 to 07:8 Adjustable from 1 to 8 Od:1 Do not adjust! Od:2 Do not adjust! 21:1 to 21:100 The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h; 1 step 100 h 23:1 to 23:24 Interval adjustable from 1 to 24 months. 24:1 “Service” display. The address is automatically set and must be manually reset after a service has been carried out. 2b:1 to 2b:60 Maximum preheating time of isolation valve, adjustable from 1 to 60 min. 2c:1 to 2c:60 Maximum shutdown delay of isolation valve, adjustable from 1 to 60 min. “Consecutive boiler number in multi boiler systems” 07:1 Consecutive boiler number in multi boiler systems. Is not indicated for boiler section 1. Boiler section 2/boiler section 3 factory set. “Therm Control” Od:0 Without “Flue gas temperature sensor” 1f:0 Do not adjust! “Service interval” 21:0 No service interval (hours run) selected. “Interval for service” 23:0 No interval for service. ”Service” display” 24:0 No “Service” display. “Maximum preheating time of isolation valve” 2b:5 Preheating time 5 min. “Maximum shutdown delay of isolation valve” 2c:5 Shutdown delay 5 min. “Cascade” Group Coding Coding in the factory set condition Possible change “Number of boilers connected to the cascade” 126 8 boilers Factory set condition: CA3 3.5/4.0: 2 CA3 5.0/5.0: 3 35:1 to 35:8 1 to 8 boilers 5776 774 - 05 35:2 or 3 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Cascade” Group Coding level 2 (continued) Coding in the factory set condition Possible change “Minimum system supply temperature limit” 36:0 Set to 32°F (0°C). 36:1 to 36:127 Adjustable from 32 to 261°F (0 to 127°C) (only when operating with standard room temperature). 37:20 to 37:127 Adjustable from 68 to 261°F (20 to 127°C). 38:1 Boiler section 1 changeover: Every first day of the month, the boiler with the shortest number of hours run by its burner becomes the boiler section 1. Boiler section 1 changeover after 200 to 20,000 hours run 1 step 100 hours run. “Maximum system supply temperature limit” 37:80 Set to 176°F (80°C). “Boiler section 1 or boiler sequence changeover” 38:0 No boiler section 1 or boiler sequence changeover; see function description in chapter “Cascade control”. 38:2 to 38:200 “Permanent boiler section 1” 39:0 No permanent boiler section 1. “Permanent last boiler” 3a:0 No permanent last boiler. “Type of control” 3b:1 Standalone parallel boiler circuit: With supply temperature sensor (see page 182). 39:1 to 39:8 Permanent last boiler is boiler 1, 2, 3, 4, 5, 6, 7 or 8. 3a:1 to 3a:8 Permanent last boiler is boiler 1, 2 or 3. 3b:0 Standalone parallel boiler circuit: Without supply temperature sensor (see page 182). Standalone serial boiler circuit: Without supply temperature sensor (see page 182). Standalone serial boiler circuit: With supply temperature sensor (see page 182). Sequential control method with supply temperature sensor (see page 182). 3b:2 3b:3 3b:4 “Control strategy” 3c:0 Condensing strategy (see page 182). 3c:1 3c:2 “Output statement” 3d:1 Output statement for condensing 3d:0 strategy and conventional boiler strategy 1. 5776 774 - 05 Note: Value must be lower than the lowest value of coding “06” in the “Combustion controller” group of every control unit. Conventional boiler strategy 1 (see page 182). Conventional boiler strategy 2 (see page 182). No output statement Control only in accordance with conventional boiler strategy 2. 127 Coding level 2 (continued) Coding in the factory set condition “System pump” 3e:0 System pump will only run if there is a heat demand. “Tank priority control for system pump” 3f:0 Without tank priority control for system pump. “ECO threshold boiler 1” 41:31 No ECO threshold boiler 1. “ECO threshold boiler 2” 42:31 No ECO threshold boiler 2. “ECO threshold boiler 3” 43:31 No ECO threshold boiler 3. “ECO threshold boiler 4” 44:31 No ECO threshold boiler 4. “Start integral threshold” 45:60 Set to 60 K x minute. “Stop integral threshold” 46:40 Set to 40 K x minute. “Stop differential” 47:15 Set to 15 K. “ECO threshold boiler 5” 65:31 No ECO threshold boiler 5. 128 Possible change 3e:1 System pump always runs; shutdown through “External blocking” signal. 3f:1 With tank priority control for system pump. 41:−30 to 41:+30 Adjustable from -22 to 86°F (−30 to +30°C). 42:−30 to 42:+30 Adjustable from -22 to 86°F (−30 to +30°C). 43:−30 to 43:+30 Adjustable from -22 to 86°F (−30 to +30°C). 44:−30 to 44:+30 Adjustable from -22 to 86°F (−30 to +30°C). 45:1 to 45:255 Adjustable from 1 to 255 K x minute. 46:1 to 46:255 Adjustable from 1 to 255 K x minute. 47:2 to 47:30 Adjustable from 2 to 30 K 65:−30 to 65:+30 Adjustable from -22 to 86°F (−30 to +30°C). Note: A boiler or burner stage will shut down if this value is exceeded. Note: A boiler or burner stage will shut down if this value is exceeded. Note: One boiler or one burner stage will be shut down if the actual supply temperature exceeds the set supply temperature by this value. 5776 774 - 05 “Cascade” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Cascade” Group Coding level 2 (continued) Coding in the factory set condition “ECO threshold boiler 6” 6f:31 No ECO threshold boiler 6. “ECO threshold boiler 7” 74:31 No ECO threshold boiler 7. “ECO threshold boiler 8” 7d:31 No ECO threshold boiler 8. Possible change 6f:−30 to 6f:+30 Adjustable from -22 to 86°F (−30 to +30°C). 74:−30 to 74:+30 Adjustable from -22 to 86°F (−30 to +30°C). 7d:−30 to 7d:+30 Adjustable from -22 to 86°F (−30 to +30°C). “DHW” Group Coding Coding in the factory set condition “Storage tank heating, hysteresis” 55:0 Tank heating, hysteresis ± 2.5 K. Possible change 55:1 55:2 55:3 “DHW temperature target” 56:0 Set DHW temperature adjustable from 50 to 140°F (10 to 60°C). 56:1 Adaptive storage tank heating enabled (see page 191). Storage tank temperature control with 2 tank temperature sensors (see page 191). Storage tank temperature control, storage tank loading system (see page 190). Adjustable from 50 to above 140°F (10 to above 60°C). Note: Observe the max. permissible DHW temperature. “Additional function for DHW heating” 58:0 Without additional function for DHW heating. “Tank heating: Set start point” 59:0 Set start point –2.5 K Set stop point +2.5 K 5776 774 - 05 “For DHW heating” 5a:0 The set supply temperature is determined by the highest system supply temperature demand. Scan of the temperature in the “Diagnosis” menu, “General” (“Common demand temp.”). 58:10 to 58:60 Input of a second set DHW temperature; adjustable from 50 to 203°F (10 to 95°C). (observe coding “56”). 59:1 to 59:10 Adjustable from 1 to 10 K below set value. 5a:1 The supply temperature target is determined by the DHW tank supply temperature demand. Scan of the temperature in the “Diagnosis” menu, “General” (“Common demand temp.”). 129 Coding level 2 “DHW” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Coding in the factory set condition “Boiler temperature during DHW heating” 60:20 During DHW heating, the boiler water temperature is up to 20 K higher than the set DHW temperature. “DHW pump” 61:1 DHW pump starts immediately. Possible change 60:10 to 60:50 The differential between the common supply temperature and the set DHW temperature is adjustable from 10 to 50 K. 61:0 DHW pump starts subject to boiler temperature. “DHW pump delay off” 62:10 DHW pump with a delay off time of up to 10 min after tank heating. 130 5776 774 - 05 62:0 No DHW pump delay off 62:1 Delay off time adjustable from 1 to 15 to min. 62:15 “In comfort mode and after external changeover to constant operation with the standard room temperature” 64:2 Enable constant DHW heating and DHW 64:0 No DHW heating; DHW pump “OFF” pump “ON”. 64:1 DHW heating and DHW pump “ON” according to time program. “Input of the set DHW temperature” 66:4 At the programming unit of the control 66:0 At the programming unit of the unit and all installed Vitotrol 300A control unit. 66:1 At the programming unit of the control remote controls. unit and remote control unit of the heating circuit without mixing valve A1 (heating circuit 1). 66:2 At the programming unit of the control unit and remote control unit of the heating circuit with mixing valve M2 (heating circuit 2). 66:3 At the programming unit of the control unit and remote control unit of the heating circuit with mixing valve M3 (heating circuit 3). 66:5 At the remote control of the heating circuit without mixing valve A1 (heating circuit 1). 66:6 At the remote control of the heating circuit with mixing valve M2 (heating circuit 2). 66:7 At the remote control of the heating circuit with mixing valve M3 (heating circuit 3). “For solar DHW heating: DHW temperature target” 67:40 DHW setpoint temperature 104°F 67:0 No set value 3 (40°C). Reheating is suppressed above 67:10 DHW setpoint temperature adjustable the selected set temperature (DHW to from 50 to 203°F (10 to 95°C) heating by the boiler only if solar energy 67:95 (limited by boiler-specific coding). is not sufficient). Observe setting of coding “56”. “With 2 tank temperature sensors: Tank heating stop point” 68:8 With 2 tank temperature sensors (coding 68:2 Factor adjustable from 0.2 to 1 “55:2”): Tank heating stop point at set to 1 step 0.1 value x 0.8. 68:10 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “DHW” Group Coding level 2 (continued) Coding in the factory set condition Possible change “With 2 tank temperature sensors: Tank heating start point” 69:7 With 2 tank temperature sensors (coding 69:1 “55:2”): Tank heating start point at set to value x 0.7. 69:9 “Runtime, actuator, mixing valve, heat exchanger set, Vitotrans 222” 6A:75 Runtime, servomotor, mixing valve, heat 6A:10 exchanger set, Vitotrans 222, (80 and to 120 kW): 75 sec. 6A:255 “DHW recirculation pump” 70:0 DHW recirculation pump “ON” according 70:1 to time program when DHW heating is enabled. 71:0 DHW recirculation pump “ON” according 71:1 71:2 to time program. Factor adjustable from 0.1 to 0.9 1 step 0.1. For heat exchanger set Vitotrans 222 (240 kW): set 113 sec. Runtime adjustable from 10 to 255 sec. DHW recirculation pump “ON” according to time program. “OFF” during DHW heating to set value 1. “ON” during DHW heating to set value 1. 72:0 DHW recirculation pump “ON” according 72:1 72:2 to time program. “OFF” during DHW heating to set value 2. “ON” during DHW heating to set value 2. 73:0 DHW recirculation pump “ON” according 73:1 to time program. to 73:6 73:7 “ON” from once per hour for 5 min up to 6 times per hour for 5 min during the time program. Constantly “ON” 75:0 DHW recirculation pump “ON” according 75:1 to time program. DHW recirculation pump “OFF” during economy mode. “Solar” Group Only in conjunction with solar control module, type SM1. 5776 774 - 05 Coding in the factory set condition Possible change “Differential between the actual DHW temperature and the start point for the solar circuit pump” 00:8 Start temperature differential for solar 00:2 Adjustable from 2 to 30 K. circuit pump 8 K to 00:30 “Differential between the actual DHW temperature and the stop point of the solar circuit pump” 01:4 Stop temperature differential for solar 01:1 Adjustable from 1 to 29 K. circuit pump 4 K to 01:29 “Solar circuit pump speed control” 02:0 Solar circuit pump is not speed-controlled 02:1 Variable speed solar circuit pump with wave packet control. 02:2 Solar circuit pump speed controlled with PWM control. 131 Coding level 2 “Solar” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) 132 5776 774 - 05 Coding in the factory set condition Possible change “Temperature differential between the collector temperature and actual DHW temperature” 03:10 Temperature differential for the start of 03:5 Adjustable from 5 to 20 K. speed control 10 K. to 03:20 “Controller amplification of the speed control” 04:4 Controller amplification of the speed 04:1 Adjustable from 1 to 10%/K. control 4%/K. to 04:10 “Minimum speed of the solar circuit pump” Adjustable from 2 to 100%. 05:10 Minimum speed of the solar circuit pump 05:2 10% of the maximum speed. to 05:100 “Maximum speed of the solar circuit pump” 06:75 Maximum speed of the solar circuit 06:1 Adjustable from 1 to 100%. pump 75% of maximum possible speed. to 06:100 “Interval function of the solar circuit pump” 07:0 Interval function of the solar circuit 07:1 Interval function of the solar circuit pump switched off. pump switched on. To capture the collector temperature more accurately, the solar circuit pump starts for short cycles. “Maximum storage tank temperature” 08:60 DHW setpoint temperature (maximum 08:10 Adjustable from 50 to 194°F tank temperature) 140°F (60°C). to (10 to 90°C). 08:90 “Maximum collector temperature” 09:130 Maximum collector temperature 09:20 Adjustable from 68 to 392°F (to protect system components) to (20 to 200°C). 266°F (130°C). 09:200 “Stagnation time reduction” 0a:5 Temperature differential for reducing the 0a:0 Stagnation time reduction disabled. stagnation time (reduction in solar circuit 0a:1 Adjustable from 1 to 40 K. pump speed to protect system components to and heat transfer medium) 5 K. 0a:40 “Frost protection function for solar circuit” 0b:0 Frost protection function for solar circuit 0b:1 Frost protection function for solar switched off. circuit switched on (not required with Viessmann heat transfer medium). “Delta T monitoring” 0c:1 Delta T monitoring switched on. No flow 0c:0 Delta T monitoring switched off. rate captured in the solar circuit, or flow rate too low. “Minimum collector temperature” 12:20 Minimum collector temperature 12:0 No minimum limit. (minimum solar circuit pump start 12:1 Adjustable from 34 to 194°F temperature) 68°F (20°C). to (1 to 90°C). 12:90 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Solar” Group (continued) Coding in the factory set condition “Night circulation monitoring” 0d:1 Night circulation monitoring switched on. Unintentional flow in the solar circuit is captured (e.g. at night). “Calculation of solar yield” 0e:1 Heat statement in conjunction with Viessmann heat transfer medium Possible change 0d:0 Night circulation monitoring switched off. 0e:2 0e:0 Do not adjust! No heat statement. “Solar circuit flow rate” 0F:70 Solar circuit flow rate at maximum pump 0f:1 speed 1.8 USG/min (7 L/min) to 0f:255 “Target temperature control” 10:0 Target temperature control OFF 10:1 (see coding address “11”) “Set solar DHW temperature” 11:50 Set solar DHW temperature 122°F (50°C) 11:10 to H Target temperature control switched 11:90 on (code “10:1”): Flow rate adjustable from 0.02 to 6.7 USG/min (0.1 to 25.5 L/min) 1 step 0.02 USG/min (0.1 L/min). Target temperature control switched on. Adjustable from 50 to 194°F (10 to 90°C). Temperature at which the water in the DHW tank heated by solar energy is to be stratified. 5776 774 - 05 H Code “20:9” (heating of two DHW tanks) selected: When one DHW tank reaches its set DHW temperature, the second DHW tank is heated. “Minimum collector temperature” 12:20 Minimum collector temperature (minimum solar circuit pump start temperature) 68°F (20°C). 12:0 12:1 to 12:90 No minimum limit Adjustable from 34 to 194°F (1 to 90°C). 133 Coding level 2 (continued) Coding in the factory set condition “Extended control function” 20:0 No extended control function enabled. Possible change 20:1 20:2 20:3 20:4 20:5 20:6 20:7 20:8 20:9 “Start temperature differential for central heating backup” 22:8 Start temperature differential with central heating backup 8 K (code “20:4” must be set). “Stop temperature differential for central heating backup” 23:4 Stop temperature differential with central heating backup 4 K (code “20:4” must be set). “Start temperature for thermostat function” 24:40 Start temperature for thermostat function 104°F (40°C) (coding “20:5”or “20:6” must be set). “Stop temperature for thermostat function” 25:50 Stop temperature for thermostat function 122°F (50°C) (coding “20:5”or “20:6” must be set). “Priority for DHW storage tank 1” 26:1 Priority for DHW storage tank 1 with cyclical heating (code “20:9” must be set). 22:2 to 22:30 Start temperature differential adjustable from 2 to 30 K. 23:2 to 23:30 Stop temperature differential adjustable from 1 to 29 K. 24:0 to 24:100 Adjustable from 0 to 100 K 25:0 to 25:100 Adjustable from 0 to 100 K. 26:0 Priority for DHW storage tank 1 without cyclical heating. Priority for DHW storage tank 2 without cyclical heating. Priority for DHW storage tank 2 with cyclical heating. Alternate heating without priority for one of the DHW storage tanks . 26:2 26:3 26:4 134 Additional function for DHW heating. Differential temperature control 2. Differential temperature control 2 and auxiliary function. Differential temperature control 2 for central heating backup. Thermostat function Thermostat function and auxiliary function. Solar heating via external heat exchanger without additional temperature sensor. Solar heating via external heat exchanger with additional temperature sensor. Solar heating of two DHW storage tanks [Solar heating of two DHW tanks]. 5776 774 - 05 “Solar” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Solar” Group (continued) Coding in the factory set condition “Alternate heating time” 27:15 Alternate heating time 15 min The DHW tank without priority is heated at most for the duration of the set cyclical heating duration if the DHW tank with priority is already heated up. “Alternate pause time” 28:3 Alternate pause time 3 min After the selected cyclical heating duration for the DHW tank without priority has expired, the rise in collector temperature is captured during the cyclical pause time. Possible change 27:5 to 27:60 Adjustable from 5 to 60 min. 28:1 to 28:60 Adjustable from 1 to 60 min.. “Heating Circuit ...” Group Coding Coding in the factory set condition “Remote control” Possible change a0:0 a0:1 Without remote control. a0:2 “Blocking remote control” a1:0 All possible settings at the remote control can be accessed. “Storage tank priority” a2:2 Tank priority for heating circuit pump and mixing valve. a1:1 Only comfort mode can be set at the remote control. a2:0 Without storage tank priority applicable to heating circuit pump and mixing valve Storage tank priority only applicable to mixing valve. Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat. a2:1 a2:3 to a2:15 “Temperature limits frost protection function” a3:2 Outdoor temperature below 34°F (1°C): Heating circ pump switched on. Outdoor temperature above 37°F (3°C): Heating circ pump switched off. With Vitotrol 200, recognized automatically. Recognized automatically with Vitotrol 300. a3:–9 to a3:15 Heating circuit pump ON/OFF (see the following table). CAUTION 5776 774 - 05 If a value below 34°F (1°C) is selected, there is a risk that pipes outside the thermal envelope of the house could freeze up. Standby mode in particular should be taken into consideration, e.g. during holidays. 135 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group (continued) Coding address a3:... Heating circuit pump Heating circuit pump “ON” Heating circuit pump “OFF” -9 14°F (–10°C) 18°F (–8°C) -8 16°F (–9°C) 19.5°F (–7°C) -7 18°F (–8°C) 21°F (–6°C) -6 19.5°F (–7°C) 23°F (–5°C) -5 21°F (–6°C) 25°F (–4°C) -4 23°F (–5°C) 27°F (–3°C) -3 25°F (–4°C) 28.5°F (–2°C) -2 27°F (–3°C) 30°F (–1°C) -1 28.5°F (–2°C) 32°F (0°C) 0 30°F (–1°C) 34°F (+1°C) 1 32°F (0°C) 36°F (+2°C) 2 to 15 34°F (+1°C) to 57 F (+14°C) 27°F (+3°C) to 61°F (+16°C) Coding in the factory set condition “Frost protection” a4:0 With frost protection Possible change a4:1 No frost protection; this setting is only possible if code a3:9 has been selected. Note: “Important” also coding address “a3”. “Heating circuit pump logic function (economy control)” a5:5 With heating circuit pump logic function (economy control): heating circuit pump OFF when the outdoor temperature (OT) is 1 K higher than the set room temperature (RTset) OT > RTset +1 K. a5:1 to a5:15 Without heating circuit pump logic function. With heating circuit pump logic function: Heating circuit pump OFF, see the following table. Coding address a5:... With heating circuit pump logic function: Heating circuit pump “OFF” 1 OT > RTset + 5 K 2 OT > RTset + 4 K 3 OT > RTset + 3 K 4 OT > RTset + 2 K 5 OT > RTset + 1 K 6 OT > RTset 7 to 15 OT > RTset – 1 K OT > RTset – 9 K 5776 774 - 05 136 a5:0 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group Coding level 2 (continued) Coding in the factory set condition “Extended economy mode” a6:36 Extended economy mode disabled. “Mixing valve economy function” a7:0 Only for heating circuits with mixing valve: Without mixing valve economy function. Possible change a6:5 to a6:35 Extended economy mode enabled, i.e. the burner and heating circuit pump will stop and the mixing valve will be closed at a variable value, adjustable between 41 to 95°F (5 and 35°C) plus 2°F (1°C). The base value is the adjusted outdoor temperature. This value is based on the actual outdoor temperature and a time constant, which takes the cooling down of an average building into consideration. a7:1 With mixing valve economy function: Heating circuit pump also OFF: H Mixing valve switched on to heating circuit pump longer than 20 min: H Mixing valve in control mode H If there is a risk of frost “Pump idle time” a9:0 Without pump idle time. “Output reduction” aa:2 With output reduction through temperature sensor aJA. “Room temperature hook-up” b0:0 With remote control:*1 Heating mode/reduced mode: Weather-compensated. a9:1 to a9:15 Pump idle time adjustable from 1 to 15. 1: Short idle time 15: Long idle time aa:0 aa:1 Without output reduction. No function. b0:1 Heating mode: Weather-compensated Reduced mode: with room temperature hook-up Heating mode: with room temperature hook-up Reduced mode: Weather-compensated Heating mode/reduced mode: with room temperature hook-up. b0:2 b0:3 “Room influence factor” b2:8 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed: Room influence factor 8. b2:0 b2:1 to b2:31 “Room temperature-dependent heating circuit pump logic function” b5:0 With remote control: b5:1 No room temperature-dependent to heating circuit pump logic function. b5:8 Without room influence. Adjustable from 1 to 31. For heating circuit pump logic function, see the table on page 138. 5776 774 - 05 *1 Only change the coding for the heating circuit without mixing valve A1 for boilers without lower temperature limit or for heating circuits with mixing valve if a remote control is connected to them. 137 Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group (continued) Coding address b5:... With heating circuit pump logic function: Heating circuit pump “OFF” 1 RTactual > RTset + 5 K RTactual < RTset + 4 K 2 RTactual > RTset + 4 K RTactual < RTset + 3 K 3 RTactual > RTset + 3 K RTactual < RTset + 2 K 4 RTactual > RTset + 2 K RTactual < RTset + 1 K 5 RTactual > RTset + 1 K RTactual < RTset 6 RTactual > RTset RTactual < RTset – 1 K 7 RTactual > RTset – 1 K RTactual < RTset – 2 K 8 RTactual > RTset – 2 K RTactual < RTset – 3 K “Heat-up gradient start optimization” b8:10 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed: Heat-up gradient start optimization 10 min/K. “Learning start optimization” b9:0 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed: Without learning start optimization. “Shutdown time optimization” c0:0 With remote control: Without shutdown time optimization. Possible change b6:1 With quick heat-up/quick setback. (see function description on page 185). b7:1 With start optimization, max. heat-up time offset 2 h 30 min. With start optimization, max. heat-up time offset 15 h 50 min. b7:2 b8:11 to b8:255 Adjustable from 11 to 255 min/K b9:1 With learning start optimization c0:1 With stop optimization, max. setback time offset 1 h. With stop optimization, max. setback time offset 2 h. c0:2 “Stop optimization of setback time offset” c1:0 With remote control: Without shutdown time optimization. “Learning shut-down time optimization” c2:0 With remote control: Without learning shutdown time optimization. 138 c1:1 to c1:12 With stop optimization of setback time offset adjustable from 10 to 120 min. 1 step 10 min. c2:1 With learning shut-down time optimization. 5776 774 - 05 Coding in the factory set condition “Quick heat-up/quick setback” b6:0 With remote control: Without quick heat-up/quick setback. “Start optimization” b7:0 With remote control and for the heating circuit, operation with room temperature. hook-up must be programmed: Without start optimization. Heating circuit pump “ON” Coding level 2 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service “Heating Circuit ...” Group (continued) Coding in the factory set condition “Mixing valve runtime” c3:125 Only for heating circuits with mixing valve: Mixing valve runtime 125 sec. “System dynamics mixing valve” c4:1 System dynamics: Mixing valve control characteristics. “Minimum supply temperature limit” c5:20 Electronic minimum supply temperature limit 68°F (20°C) (only when operating with standard room temperature). “Maximum supply temperature limit” c6:75 Electronic maximum supply temperature limit set to 167°F (75°C). “Room influence limit” c8:31 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed: No room influence limit “External operating program changeover” d5:0 With external operating program changeover (observe setting of coding “5d”, “5e”, “5f” and “91” in the “General” group). Changeover “Constant central heating with reduced room temperature” or “Standby mode” (subject to set reduced room temperature). “EA1 extension: Operating program changeover” d8:0 No operating program changeover. Possible change c3:10 to c3:255 Adjustable from 10 to 255 sec. c4:0 to c4:3 Controller responds too quickly (cycles between “Open” and “Closed”): Select a lower value. Controller responds too slowly (temperature is not held sufficiently): select a higher value. c5:1 to c5:127 Adjustable from 34 to 261°F (1 to 127°C) (limited by boiler specific coding). c6:10 to c6:127 Adjustable from 50 to 261°F (10 to 127°C) (limited by boiler specific coding). c8:1 to c8:30 Adjustable from 1 to 30 K. d5:1 Changeover to “Constant operation with standard room temperature”. d8:1 Operating program changeover via input DE1. Operating program changeover via input DE2. Operating program changeover via input DE3. d8:2 d8:3 5776 774 - 05 “Day temperature target” e1:1 Do not adjust! “Display correction of the actual room temperature” e2:50 With remote control: No display correction of the actual room temperature. e2:0 to e2:49 e2:51 to e2:99 Display to Display Display to Display correction –5 K correction –0.1 K correction +0.1 K correction +4.9 K 139 Coding level 2 “Heating Circuit ...” Group Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) Coding in the factory set condition “Slab curing” f1:0 Slab curing function not active. Do not adjust! “Time limit for comfort mode” f2:8 Time limit for comfort mode or external operating program changeover via pushbutton: 8 h. Possible change f2:0 No time limit*2 Note: Observe setting of coding “5d”, “5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” group. “Temperature limit for terminating reduced mode” f8:–5 Temperature limit for terminating reduced mode 23°F (–5°C), see example on page 189. Observe coding “a3”. f2:1 to f2:12 Time limit adjustable from 1 to 12 h*2. f8:+10 to f8:–60 Adjustable from 50 to -76°F (+10 to –60°C). f8:–61 Function disabled “Temperature limit for raising the reduced room temperature target” f9:–14 Temperature limit for raising the reduced f9:+10 room temperature target 7°F (-14°C), to see example on page 189. f9:–60 140 5776 774 - 05 Limit for raising the set room temperature to the value selected for standard mode, adjustable from 50 to -76°F (+10 to –60°C). “Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature” fa:20 Raising the set boiler water or fa:0 Adjustable from 0 to 50%. supply temperature when changing to from operation with reduced room fa:50 temperature to operation with standard room temperature by 20%. See example on page 189. “Duration for raising the set boiler water or supply temperature” fb:60 Duration for raising the set supply fb:0 Adjustable from 0 to 300 min. temperature (see coding “fa”) 60 min. to See example on page 189. fb:300 Service Scans Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Calling up the Service Menu From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. Select the required menu range. Overview of menu structure “Service main menu” “Diagnosis” “General” “Cascade” “DHW” “Heating circuit 1/2/3” “Solar energy” “Short query” “Reset data” “Actuator test” “System configuration” “Coding level 1” “Coding level 2” “History of faults” “Service functions” “LON participant check” “System log” “Vitocom PIN input” “Startup” “The heating system is reset to the factory state” “Change passwords” “Service level” “Coding level 2” “Reset all passwords” “Exit service” Note: H “Coding level 2” is only displayed if this level has been enabled: Enter “viexpert” password. 5776 774 - 05 H Tap to return to the “Service main menu” 141 Service Scans Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Leaving the Service Menu From the service main menu tap the following buttons: 1. “Exit service” 2. Confirm “Terminate service?” with OK. Note: The system exits the service menu automatically after 30 min. Change Passwords In the factory set condition, the following passwords have been assigned: H “viservice” for access to the “Service main menu” H “viexpert” for access to “Coding level 2” From the home screen tap the following buttons: 7. Confirm with OK. 8. Enter new password. 9. Tap OK twice. New password for “Service main menu”: 1. “Menu” 2. “Service” 3. Enter “viservice” password. New password for “Coding level 2”: 4. “Change passwords” 5. “Service level” or “Coding level 2” 6. Enter current password. Resetting all Passwords to Factory Settings From the home screen tap the following buttons: 1. Request the master password from the Technical Service at the Viessmann Group. 2. “Menu” 3. “Service” 5. “Change passwords” 6. “Reset all passwords” 7. Enter master password. This must be requested from the service hotline. 8. Confirm twice with OK. 4. Enter “viservice” password. Scanning Operating Data From the home screen tap the following buttons: For further information on operating data, see chapter “Brief scan”. 3. Enter “viservice” password. Note: “- - -” appears on the display if a scanned sensor is faulty. 5. Select required group, e.g. “General”. 1. “Menu” 2. “Service” 4. “Diagnosis” 5776 774 - 05 142 Operating data can be scanned in various areas. Operating data on heating circuits with mixing valves and a solar thermal system can only be scanned if the relevant components are installed in the system. Service Scans Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Resetting Operating Data Saved operating data (e.g. hours run) can be reset to 0. The value "Dampened outdoor temp" is reset to the actual value. From the home screen tap the following buttons: 1. "Menu" 4. "Diagnosis" 2. "Service" 5. "Reset data" 3. Enter "viservice" password. 6. Select required value or "All details". Brief Scan From the home screen tap the following buttons: 6. “Code” An overview of brief scans appears with 11 lines and 6 fields. for the required brief scan in line with the following tables. 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “Diagnosis” 5776 774 - 05 5. “Short query” 1: 2: 3: 1 2 System schemes 01 to 10 0 0 0 0 3 4 Control unit software version 0 Number of KM BUS participants 4: 5: 0 0 0 0 0 0 0 0 6: Connection on plug aVD.1/2 0: Contact open 1: Contact closed Connection on 0 plug aVD.2/3 0: Contact open 1: Contact closed 0 5 6 Software version, programming unit Appliance identification CU-ID Software version Solar control module type SM1 0 0 Software version, Software version, AM1 extension EA1 extension 0 0 143 Service Scans Brief Scan 7: 8: 9: 10: 11: Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service (continued) 1 2 LON subnet address/system number SNVT config. Software version 0: Auto Communic. 1: Tool coproc. Heating circuit HC1 Remote control Software version Remote control 0: Without 1: Vitotrol 200A 2: Vitotrol 300A 0 0 0 0 3 4 LON node address Neuron Chip Software version 5 6 0 0 Participant number Heating circuit HC2 Remote control Software version 0: Without Remote control 1: Vitotrol 200A 2: Vitotrol 300A 0 0 Software 0 version, extension for heating circuits 2 and 3 with mixing valve Heating circuit HC3 Remote control Software version 0: Without Remote control 1: Vitotrol 200A 2: Vitotrol 300A 0 0 Software 0 version, extension for heating circuits 2 and 3 with mixing valve Note: The displays in fields 3 and 5 are the same. Carrying Out an Actuator Test From the home screen tap the following buttons: 1. “Menu” Note: Before an actuator is selected, all actuators are switched to zero volt. The actuators listed in the table can be tested at the relay outputs subject to system equipment level and control unit configuration (single or multi boiler system). 2. “Service” 3. Enter “viservice” password. 4. “Actuator test” Display Explanation “All actuators” OFF All actuators have been switched off. “Output 20” ON Actuator at output sÖ A1 “Output 52” Open Actuator at output gS A1 “Output 52” Neutral “Output 52” Close “DHW tank primary pump” ON Actuator at output sA “DHW circ pump” ON Actuator at output sK “Output 29” ON Actuator at output sL “Central fault message” ON Central fault message facility at output gÖ “Htg circ pump HC2” ON Actuator at output sÖ M2 “Mixing valve HC2” Open Actuator at output gS M2 “Htg circ pump HC3” ON Actuator at output gS M3 “Mixing valve HC3” Open Actuator at output gS M3 Close 144 5776 774 - 05 Close Service Scans Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Carrying Out an Actuator Test Display (continued) Explanation “EA1 output 1” ON Contact “P - S” on plug aBJ of EA1 extension closed. “AM1 output 1” ON Actuator at output A1 “AM1 output 2” ON Actuator at output A2 “Solar circuit pump” ON “Solar circuit pump” On Solar circuit pump at output sF at solar control module, type SM1 “Solar circ pump min” ON “Solar circ pump min” On Solar circuit pump at output sF at solar control module, type SM1 set to min. speed. “Solar circ pump max” ON “Solar circ pump min” On Solar circuit pump at output sF at solar control module, type SM1 set to max. speed. “SM1 output 22” ON Actuator at output sS at solar control module type SM1 Information regarding the mixing valve motor rotational direction. The supply temperature must rise when the mixing valve opens. If the temperature drops, either the motor is turning in the wrong direction or the mixing valve set is incorrectly fitted (observe the mixing valve installation instructions). Checking Sensors From the home screen tap the following buttons: 1. “Menu” 4. “Diagnosis” 2. “Service” 5. Select group. 3. Enter “viservice” password. 6. Scan actual temperature of the relevant sensor. Maintenance Display Set limits in coding “21” and “23” in the “Boiler” group. Once these values have been reached, “Service” and appear on the display. symbol Tap the following buttons: 1. “Confirm” The footer shows . 2. Note: After tapping the following will be displayed if your heating system has several fault messages simultaneously: 3. “Service messages” The service messages appear yellow in a list. After maintenance has been carried out From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “Service functions” 5776 774 - 05 5. “Reset service” The set service coding for hours run and interval restart at 0 and coding “24” in the “Boiler” group is set to “24:0”. Note: If a service is carried out prematurely, set coding “24:1” in the “Boiler” group to “24:0”. The selected maintenance coding for hours run and time intervals restart at 0. If coding “24” is not reset, “Service” will be displayed again on the following Monday. 145 Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Fault Display In the event of a fault, the red fault display flashes at the and “Fault”. control unit. The display shows symbol Note: If a central fault message facility is connected, this is started. For an explanation of fault messages, see chapter “Fault messages”. Calling up acknowledged fault messages Tap the following buttons: 1. Note: After tapping the following will be displayed if your heating system has several fault messages simultaneously: 2. “Faults” The fault messages appear in red and in chronological order in a list. Calling up fault codes from the fault memory (fault history) The 10 most recent faults (including those remedied) are saved and can be scanned. Faults are sorted by date. From the home screen tap the following buttons: 1. “Menu” 2. “Service” 3. Enter “viservice” password. 4. “History of faults” 5. Call up further information in the relevant fault with ?. 146 5776 774 - 05 6. Tap “Reset” to delete the list. Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler System Fault Codes Displayed fault code System characteristics Cause Measures 0f Control mode. Service “0f” is only displayed in the fault history. Service required Note: After servicing, set code “24:0”. 10 Operates as if the outdoor temperature was 32°F (0°C). Short circuit, outdoor temperature sensor. Check outdoor temperature sensor. 18 Operates as if the outdoor temperature was 32°F (0°C). Lead break, outdoor temperature sensor. Check outdoor temperature sensor. 20 Standalone control unit without supply temperature sensor (possibly supply temperature not high enough) Short circuit, common supply temperature sensor Check the supply temperature sensor. 28 Standalone control unit without supply temperature sensor (possibly supply temperature not high enough) Lead break, common supply temperature sensor Check the supply temperature sensor. 30 H With DHW tank: DHW pump ON, boiler is maintained at set tank temperature. Short circuit, boiler water temperature sensor Check boiler water temperature sensor. Lead break, boiler water temperature sensor Check boiler water temperature sensor. H Without DHW tank: Boiler is regulated by the temperature controller. 38 H With DHW tank: DHW pump ON, boiler is maintained at set tank temperature. 5776 774 - 05 H Without DHW tank: Boiler is regulated by the temperature controller. 40 Mixing valve is being closed. Short circuit, supply temperature Check supply temperature sensor, heating circuit with mixing sensor. valve M2 (heating circuit 2). 44 Mixing valve is being closed. Short circuit, supply temperature Check supply temperature sensor, heating circuit with mixing sensor. valve M3 (heating circuit 3). 48 Mixing valve is being closed. Lead break, supply temperature Check supply temperature sensor, heating circuit with mixing sensor. valve M2 (heating circuit 2). 147 Troubleshooting 148 (continued) Displayed fault code System characteristics Cause Measures 4c Mixing valve is being closed. Lead break, supply temperature sensor, heating circuit with mixing valve M3 (heating circuit 3). Check supply temperature sensor. 50 Tank loading pump on: DHW temperature target = set supply temperature Priority control is cancelled. Short circuit, tank temperature sensor 1 Check tank temperature sensor. 52 Control mode Short circuit, supply temperature sensor low loss header. Check supply temperature sensor. 58 Tank loading pump on: DHW temperature target = set supply temperature Priority control is cancelled. Lead break, DHW tank temperature sensor 1. Check DHW tank temperature sensor. 5a Control mode Lead break, low loss header supply temperature sensor. Check supply temperature sensor (see page 194). Without supply temperature sensor: Set code “52:0” in the “General” group. 60 Boiler with maximum temperature, no output reduction, mixing valve return temperature control open Short circuit, temperature sensor aJA. Check temperature sensor. 68 Boiler with maximum temperature, no output reduction, mixing valve return temperature control open Lead break, temperature sensor aJA. Check temperature sensor. Without temperature sensor: Set coding “4a:0” in the “General” group. 70 Shunt pump constantly ON. With tank loading system: close 3-way mixing valve; no DHW heating Short circuit, temperature sensor aJB. Check temperature sensor. 78 Shunt pump constantly ON With tank loading system: close 3-way mixing valve; no DHW heating Lead break, temperature sensor aJB. Check temperature sensor. Without temperature sensor: Set code “4b:0” in the “General” group. 80 If a fault occurs 3 x in 15 min., fault is displayed. Burner control unit goes into a fault state, system cools down, burner control unit locked out. Short circuit, boiler water temperature sensor, burner control unit Check connection cable and dual sensor; replace sensor if required. 81 Burner control unit in a fault sate Sensor drift, boiler water temperature sensor, burner control unit Check connection cable and dual sensor; replace sensor if required. 82 Burner control unit in a fault state, system cools down, burner control unit locked out. Short circuit, flue gas temperature Check connection cable and sensor (A or B), burner control sensors (A and B), replace unit sensors if required. 5776 774 - 05 Boiler System Fault Codes Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service 5776 774 - 05 Boiler System Fault Codes (continued) Displayed fault code System characteristics Cause Measures 83 If a fault occurs 3 x in 15 min., fault is displayed. Burner control unit goes into a fault state. Sensor drift, flue gas temperature Check connection cable and sensor (A or B), burner control sensors (A and B), replace unit sensors if required. 88 Burner control unit in a fault state Lead break, boiler water temperature sensor, burner control unit Check connection cable and dual sensor; replace sensor if required. 89 Burner control unit in a fault state Lead break, flue gas temperature sensor (A or B), burner control unit Check connection cable and sensors (A and B), replace sensor if required. 90 Control mode Short circuit, temperature sensor / connection at solar control module, type SM1. Check temperature sensor / (see separate installation and service instructions). 91 Control mode Short circuit, temperature sensor aÖ, connection at solar control module, type SM1. Check temperature sensor aÖ (see separate installation and service instructions). 92 No solar DHW heating. Short circuit, collector Check sensor at the solar control unit (see separate installation and temperature sensor, connection of temperature sensor & at solar service instructions). control module, type SM1 or sensor at S1 of the Vitosolic. 93 Control mode. Short circuit, temperature sensor, Check sensor at the solar control connection at S3 of the Vitosolic. unit (see separate installation and service instructions). 94 No solar DHW heating. Short circuit, DHW tank Check sensor at the solar control temperature sensor, connection unit (see separate installation and of temperature sensor % at solar service instructions). control module, type SM1 or sensor at S2 of the Vitosolic. 98 Control mode Lead break, temperature sensor /, connection at solar control module, type SM1. Check temperature sensor / (see separate installation and service instructions). Check coding address “20” in the “Solar” group. 99 Control mode Lead break, temperature sensor aÖ, connection at solar control module, type SM1. Check temperature sensor aÖ (see separate installation and service instructions). Check coding address “20” in the “Solar” group. 9a No solar DHW heating. Lead break, collector temperature Check sensor at the solar control sensor, connection of unit (see separate installation and temperature sensor & at solar service instructions). control module, type SM1 or sensor at S1 of the Vitosolic. 149 Troubleshooting 150 (continued) Displayed fault code System characteristics Cause Measures 9b Control mode Lead break, temperature sensor, Check sensor at the solar control connection to S3 of the Vitosolic. unit (see separate installation and service instructions). 9c No solar DHW heating. Lead break, DHW tank temperature sensor, connection of temperature sensor % at solar control module, type SM1 or sensor at S2 of the Vitosolic. Check sensor at the solar control unit (see separate installation and service instructions). 9e Control mode No supply rate in solar circuit or flow rate too low, or temperature limiter has responded. Check solar circuit. Acknowledge fault message (see separate installation and service instructions). 9f Control mode Fault, solar control module, type SM1 or Vitosolic. Displayed if a fault occurs at these devices that has no fault message in the Vitotronic. Check solar control unit (see separate installation and service instructions). a0 Boiler cools down Fault, safety equipment at “X7” of plug-in adapter 2 for external safety equipment Check safety equipment, reset if required. a1 Boiler cools down Fault, safety equipment at “X3” of plug-in adapter 2 for external safety equipment Check safety equipment, reset if required. a2 Boiler cools down Fault, safety equipment at “X2” of plug-in adapter 2 for external safety equipment Check safety equipment, reset if required. a3 Boiler cools down Fault, safety equipment at “X1” of plug-in adapter 2 for external safety equipment Check safety equipment, reset if required. a7 Control mode Programming unit fault Replace the programming unit. ab Control mode, DHW tank may be cold Tank loading system configuration fault: Coding “55:3” in the “DHW” group has been set, but plug aJB is not plugged in and/or codes “4c:1” and “4e:2” in the “General” group have not been set. Insert plug aJB and check codes. b1 Control mode Communication error, programming unit Check connections, and replace the programming unit if required. b5 Control mode Internal fault Check PCB is plugged in correctly. 5776 774 - 05 Boiler System Fault Codes Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler System Fault Codes (continued) Displayed fault code System characteristics Cause Measures b6 Constant mode Invalid hardware recognition Check coding address “92” in the “General” group; H 161: Single boiler system H 190: Cascade control unit 5776 774 - 05 H 166: Boiler section 2/boiler section 3 control unit Note: Coding “8a:176” in the “General” group must be set in order for coding “92” to be able to be displayed. b7 Boiler water temperature control Coding card fault Plug in or replace the boiler coding card. b8 Control mode Lead break, flue gas temperature sensor Replace temperature sensor. Set code “1F:0” in the “Boiler” group. ba Mixing valve close Communication error, PCB, extension for heating circuits 2 and 3 with mixing valve. Check that the PCB and ribbon cable are plugged in correctly, and replace PCB if required. bc Control mode without remote control. Communication error, Vitotrol remote control unit, heating circuit without mixing valve A1 (heating circuit 1). Check connections, lead (see separate installation and service instructions) and coding address “a0” in the “Heating circuit...” group. bd Control mode without remote control Communication error, Vitotrol remote control unit, heating circuit with mixing valve M2 (heating circuit 2) Check connections, lead (see separate installation and service instructions) and coding address “a0” in the “Heating circuit...” group. be Control mode without remote control Communication error, Vitotrol remote control unit, heating circuit with mixing valve M3 (heating circuit 3) Check connections, lead (see separate installation and service instructions) and coding address “a0” in the “Heating circuit...” group. bf Control mode No communication via LON Incorrect LON communication module. Replace LON communication module. c1 Boiler cools down External safety equipment at plug Check connection and external aBÖ. safety equipment. c2 Control mode Lead break, KM BUS to solar control module, type SM1 or Vitosolic. Check KM BUS cable and appliance. Without solar control unit: Set code “54:0” in the “General” group. c3 Control mode Communication error, AM1 extension Check connections. Without AM1 extension: Set coding “32:0” in the “General” group. c8 Boiler cools down. Fault, low water indicator at “X7” of plug-in adapter 1 for external safety equipment. Check system water level, reset low water indicator. 151 Troubleshooting 152 (continued) Displayed fault code System characteristics Cause Measures c9 Boiler cools down. Fault, maximum pressure limiter at “X3” of plug-in adapter 1 for external safety equipment Check system pressure, reset maximum pressure limiter. cA Boiler cools down. Fault, minimum pressure limiter or maximum pressure limiter 2 at “X2” of plug-in adapter 1 for external safety equipment Check system pressure, reset minimum pressure limiter or maximum pressure limiter 2. cB Boiler cools down. Fault at additional safety temperature limiter or temperature monitor at “X1” of plug-in adapter 1 for external safety equipment Check system temperature, reset safety temperature limiter. cF Control mode No communication via LON, boiler at a configerable temperature set point Communication error, control unit LON communication module. Check LON communication module and replace if required. If no LON communication module is installed, set code “76:0” in the “General” group. d1 Boiler cools down. Burner in fault mode Check burner d2 Control mode Communication fault, Plug-in adapter 2 for external safety equipment Check plug-in adapter , if no plug-in adapter is available, adjust coding “31:0” in “General” group. d3 Control mode Communication error, extension EA1. Check connections (see page 122). Without extension EA1: Set code “5b:0” in the “General” group. d4 Boiler cools down MCB F2 has responded. Connection plug aBA broken. Check MCB F2 and jumper on plug aBA. Fuse F2 has tripped or check connection to Plug aBA, possibly plug aBA not inserted. d5 Boiler ramps up to the electronic maximum boiler water temperature limit. No communication between boiler circuit control unit and cascade control unit. Check communication via participants check. Check configuration of cascade participants. d6 Control mode Input DE1 at extension EA1 reports a fault. Remove fault at appliance concerned. d7 Control mode Input DE2 at extension EA1 reports a fault. Remove fault at appliance concerned. d8 Control mode Input DE3 at extension EA1 reports a fault. Remove fault at appliance concerned. da Control mode without room influence. Short circuit, room temperature Check room temperature sensor, heating circuit without sensor (see page 194). mixing valve A1 (heating circuit 1). db Control mode without room influence Short circuit, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2). Check room temperature sensor (see page 194). 5776 774 - 05 Boiler System Fault Codes Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler System Fault Codes (continued) Displayed fault code System characteristics Cause Measures dc Control mode without room influence. Short circuit, room temperature sensor, heating circuit with mixing valve M3 (heating circuit 3). Check room temperature sensor (see page 194). dd Control mode without room influence. Lead break, room temperature sensor, heating circuit without mixing valve A1 (heating circuit 1). Check room temperature sensor (see page 194). de Control mode without room influence. Lead break, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2). Check room temperature sensor (see page 194). df Control mode without room influence. Lead break, room temperature sensor, heating circuit with mixing valve M3 (heating circuit 3). Check room temperature sensor (see page 194). Burner Fault Codes 5776 774 - 05 Fault display on the display interface of the control unit. Displayed fault code System characteristics Cause Measures E1 Burner control unit in a fault state. Valve 1 not tight / gas pressure switch 2 does not open. Check setting of gas pressure switch 2; check connecting cable; replace gas valve. E2 Burner control unit in a fault state. Valve 2 not tight; gas pressure switch 2 does not close. Check setting of gas pressure switch 2; check connecting cable; replace gas valve. Shortage of gas to gas pressure switch 2; valve leak test. Gas valve does not open; gas valve leaking; gas pressure switch 2 faulty. Replace gas valve. E3 Burner control unit in a fault state. Lead break, strapping plug fJ. Check strapping plug fJ. E4 Burner shuts down Multiple detection of undervoltage with return and renewed undervoltage. Check the power supply. E5 Burner control unit in a fault state. Internal fault of the burner control unit and during test of ionization input. Replace burner control unit. EE Burner control unit in a fault state. Internal error in feedback from gas safety valves; output relay does not respond. Reset burner control unit; replace burner control unit. EF Burner control unit in a fault state. Internal error in feedback from gas safety valves; output relay does not respond. Reset burner control unit; replace burner control unit. F0 Operation according to internal burner control unit defaults. Communication error, burner control unit. Check plug and KM BUS to burner control unit. 153 Troubleshooting 154 (continued) Displayed fault code System characteristics Cause Measures F1 Burner control unit in a fault state; system cools down. Flue gas excess temperature; excessive gas throughput. Wait until temperature falls below the permissible flue gas temperature. Reset burner control unit. Check water level; check heat exchanger surfaces for contamination; check CO2 setting; set gas throughput according to rated heating output of boiler (for connection values, see boiler service instructions). F2 Burner control unit in a fault state; system cools down. Excessive boiler water temperature. Wait until temperature falls below the permissible boiler water temperature. Reset burner control unit. F3 Ionization flame monitor reports faulty flame signal during startup or after the post-purge. Gas valve not gas tight (gas is escaping and burning); incorrect coding card. Check ionization path; replace coding card; replace gas valve. F4 No flame formation during safety time; ionization flame monitor reports no flame signal. Ionization electrode incorrectly adjusted; ionization electrode not plugged in. Ground leakage of electrode or cable. Insert plug of ionization electrode; check cables; adjust ionization electrode (see boiler service instructions) No flame formation during safety time; ionization flame monitor reports no flame signal. Ignition electrodes incorrectly adjusted, electrodes grounded, faulty ignition unit, faulty burner control unit. Adjust ignition electrodes (see boiler service instructions); replace ignition unit; replace burner control unit. No flame formation during safety time; ionization flame monitor reports no flame signal. Insulation body of ignition or ionization electrode cracked. Replace ignition or ionization electrode Poor start-up characteristics; rotary damper does not close. Servomotor faulty, servomotor connecting cable faulty, output relay faulty (burner control unit). Replace connecting cable; replace servomotor; replace burner control unit. Flame does not build during the safety time, no signal captured by the ionization flame monitor. Incorrect gas type selected. Select gas type (see boiler service instructions). Flame does not build during the safety time, no signal captured by the ionization flame monitor. Gas valve does not open. Check connecting cable; check gas valve and replace if required. Flame does not build during the safety time, no signal captured by the ionization flame monitor. Combustion characteristics not ideal. Adjust the burner (see boiler service instructions); if necessary also adjust the setting screws when the burner is off to be able to start the burner). 5776 774 - 05 Burner Fault Codes Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Troubleshooting Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Fault Codes (continued) Displayed fault code System characteristics Cause Measures F5 Air pressure switch shows no air pressure, fan not running. Air pressure switch is faulty, incorrectly connected or incorrectly set. Replace air pressure switch, connect or set correctly. Air pressure switch switches off during operation. Flue gas back pressure; condensate banked up; air pressure switch hose faulty; connecting hose leaking. Remove flue gas back pressure; check if condensate banked up; reset burner control unit; replace hose. F6 Gas pressure switch notifies no gas pressure. Gas shut-off valve closed; gas pressure switch faulty; multiple problems with gas supply. Open gas shut-off valve; check gas flow pressure; replace gas filter if required; reset burner control unit; replace gas valve. F7 Fan pressure is produced during the air pressure switch idle state check. Wind influence on fan. Check the flue draught (chimney) Air pressure switch contact is not in the idle state. Air pressure switch faulty. Replace the air pressure switch. Flame extinguishes during operation. Burner gauze assembly faulty. Check burner gauze assembly; replace if damaged. Flame extinguishes during operation. Combustion characteristics not ideal. Adjust burner (see boiler service instructions). Fan not running; fan speed not reached. Fan faulty; cables are faulty or broken. Check cables and replace the fan if required Status duration too long, fan ramp-up. Internal fault; fan cannot reach its Replace fan or burner control set value. unit. Varying fan speed Fan faulty, cable a-ÖA faulty or broken. Check cable a-ÖA; check external power supply; replace the cable or fan; remove foreign bodies. Check cable; replace cable a-ÖA or fan. No fan feedback. Fan faulty, external fan power supply not connected or faulty cable a-ÖA or cable broken, fan blocked (poss. by foreign bodies). Check cable a-ÖA; check external power supply; replace cable or fan; remove foreign bodies. Fa Fan runs without demand; burner control unit in a fault state. Fan does not reach idle state, cable a-ÖA faulty, fan faulty, faulty burner control unit. Fan subject to wind influence, check flue outlet and fan, replace cable a-ÖA, replace fan, replace burner control unit. Fd Burner control unit in a fault state; system cools down; burner control unit locked out. Burner control unit in a fault state. Read off fault at the burner control unit display and programming unit (boiler service instructions). F8 F9 Fault message to the burner control unit: 5776 774 - 05 Note: If LON participant faults occur, “Fault participant”... is displayed. 155 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit Display and programming unit A display and programming unit is integrated into each burner control unit. The display indicates the relevant operating conditions, the service and parameter conditions as well as all fault and error messages, relative to that boiler section. Standby Idle state check System tests Fan ramp-up The display comprises four elements of seven segments each. Four buttons enable adjustments to be made at the different operating levels. Status display Service display Reset button LEDs, from left: heat demand, flame, maintenance and fault. F Selection button E/G Cursor button A B C D Gas valve and/or relay test Operating display In standard mode, the status display shows the current operating conditions. The same applies in a fault state after pressing reset button R C. The following displays are scrolled through automatically. In case of faults, see the fault codes from page 153. You can exit at any time by pressing and holding the reset button R C for 0.5 to 10 seconds. Pre-purge 156 5776 774 - 05 Section start-up after power supply is switched ON. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit Burner Control Unit (continued) 5776 774 - 05 Operating display (continued) Pre-ignition Maintenance program no air pressure Ignition Safety time Flame established Maintenance program no gas pressure or mains under voltage Flame stabilization Forced ventilation when no flame was recognized Operation with flame Safety shutdown due to flame tear-off Reheat Post-purge Safety shutdown due to reaching maximum boiler water temperature 157 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit (continued) Information and configuration display The information display and the configuration display are activated from the operating display. The menu selection is activated by pressing button S for longer than 2 seconds. You can scroll through the menu items with Y/B buttons. A menu item is selected by pressing button S again and will be displayed under Service. This mode is automatically terminated if no other button is pressed within 20 seconds. Information regarding current meter readings, such as the start counter and permanent hours run meter, can be called up via the information display. Information Menu item Description 1 Continuous meters for start-ups and hours run 2 Meters for start-ups and hours run that can be reset 3 Software version 4 Fault history for the last 10 fault codes Example: to delete the hours run meter, press the following buttons: 1. S longer than 2 seconds “ “ flashes 2. Y until “2“ is shown under Service. 3. S “1“ will be displayed under Status 4. Scroll through Status until “6“ is shown under Status: Y Status Description 1 Display of start-up meter with reset, 1 digit 2 Display of start-up meter with reset, 1000 digit 3 Menu item for deleting the start-up meter reading 4 Display of hours run meter with reset, 1 digit 5 Display of hours run meter with reset, 1000 digit 6 Menu item for deleting the hours run meter reading 5. S to confirm the deletion. If deleted successfully, “1“ will be shown under Service, “0“ if it failed. 6. S to change to the operating display. 158 5776 774 - 05 Menu items “5“ and “6“ are used to adjust configuration settings of the burner control unit. Note: Only make adjustments when the burner control unit is on standby. Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit (continued) Configurations: Menu item Description 5 Changeover from the operating display of the burner control unit phase to other process information 6 Configuration of control function operating parameters Menu item “5“ is used to display the following process information: Sub-menu Item Process Information Units/Scale 0 Phase 1 1 Boiler water temperature °C 2 Flue gas temperature °C 3 Ionization current I in 1/10 μA 4 Set speed % 5 PWM actuating variable % 6 Actual speed RPM x10/min 7 Gas pressure switch 1, GDW1 0 or 1 8 Gas pressure switch 2, GDW2 0 or 1 9 Air pressure switch 1, LDW1 0 or 1 A Gas valve 1 0 or 1 B Gas valve 2 0 or 1 Example: to display the ionization current, press the following buttons: 1. S longer than 2 seconds “ 2. Y “ flashes. until “5“ is shown under Service. 3. S “5“ will be displayed under Status 4. Y until “3“ is shown under Service. 5. S “3“ is shown under Status and during operation the ionization current is shown under Service (e.g. 30 = 3.0 μA). 6. To exit the process information menu, press and hold S longer than 2 seconds “_“ flashes. 7. Y until “5“ is shown under Service. 8. S “5“ will be displayed under Status 9. B until “0“ is shown under Service. 10. S to change to the operating display. 5776 774 - 05 Menu item “6“ is used to change the following operating parameters: Sub-menu Parameter Item Units/Scale Factory set condition 1 Maximum operational input % of rated input 100% 2 Gas type 0=NG (natural gas) 3 Not assigned 4 Maximum boiler water temperature from 41 to 260°F (5 to 127°C) 203°F (95°C) 5 Integral threshold value of controller In Kmin from 1 to 255 30 Kmin 6 Runtime optimization 0=minimum pause 1=integral method 1 0 Reset all operating parameters to their factory set condition 0 -- -- -- -- 159 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit (continued) Example: to set the maximum operational burner input to between 0 and 100%, press the following buttons: 1. S longer than 2 seconds “ “ flashes. 2. Y until “6“ is shown under Service. 3. S “6“ will be displayed under Status. 4. S “1” will be shown under Status and the current value for the maximum operational output in % is shown under Service. 5. Y/B for required maximum operational output. Note: Observe the modulation range. See pages 78 and 79. 6. S to confirm. If applied successfully, “1“ will be shown under Service, “0“ if it failed. 7. S to change to the operating display. Resetting Operating Parameters to Factory Settings To reset all operating parameters to factory settings, press the following buttons: 1. S longer than 2 seconds “ “ flashes. 2. Y until “6“ is shown under Service. 3. S “6“ will be displayed under Status. 4. Y until “0“ is shown under Service. 5. S “1“ is shown under Status and “dEL“ under Service. 6. S to confirm. If reset successfully, “1“ will be shown under Service, “0“ if it failed. 7. S to change to the operating display. Manual Mode and Service Display The burner must be running to call up the service display and for manual mode. The service display shows the current level of modulation in %. 160 1. B/S together for longer than 2 seconds. The burner changes to manual mode, a “P“ will be shown under Status and the current modulation level will flash under Service. 2. B for lower heating output, until “0“ is shown under Service. 3. Y for upper heating output, until “100“ is shown under Service. 4. B/S together for longer than 2 seconds. The burner returns to modulating mode. 5776 774 - 05 Press the following buttons: Output activation Input evaluation 5776 774 - 05 Valuation is performance-linked Input must be passive for continued operation Shutdown Output is active Operation Input must be active for continued operation Start-up Signal change is expected for continued operation Relay test Subsequent state depends on the parameterization of the valve test. Non-valuated input Fault message output Fan Ignition Flue gas damper Auxiliary valve/ Servomotor Gas valve V2 Gas valve V1 Requirement Flame Fan speed Air pressure switch 1 LDW1 Gas pressure switch 1 GDW1 Air pressure switch 2 LDW2 Phase System Start Wait state Error state Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit Flow Diagram Burner Control Unit 161 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit Flow Diagram (continued) State description: Phase Display Description Duration System start “A” System start 10 seconds Fan ramp-up, system start max. 20 seconds Relay test ”P“ Forced ventilation, system start 20 seconds Fan ramp-up for valve test max. 20 seconds Safety relay test 0.9 second Relay/valve test V1 2 seconds Test time V1 1.1 seconds Relay/valve test V2 2 seconds Test time V2 1.1 seconds Start-up meter, initialization 0.1 second 0 ... seconds Standby ”0“ Standby Start-up ”1“ Flame signal amplifier, test max. 50 seconds Gas fan, air pressure switch and boiler water temperature sensor test max. 20 seconds “2“ Fan ramp-up max. 20 seconds “3” Pre-purge 10 seconds Adjusting start-up load, test WD1 1.9 seconds Pre-ignition 2 seconds Ignition safety time 2.3 seconds Flame detection safety time max. 0.51 second “4” “5” Operation Shutdown “6” Flame stabilizing time 15 seconds “7” Start-up partial load 20 seconds Modulating operation 0 to 24 hours Adjusting shutdown load 0.1 seconds Reheat, test WD2 min. 10 seconds “8” Waiting Fault states 162 Fan ramp-up, post-purge max. 20 seconds Post-purge 10 seconds Waiting for restart 5 minutes ”C“ Waiting mains, gas pressure 5 minutes “9” Forced ventilation fault 20 seconds “10” Flame tear-off 0 ... seconds “11” Safety shutdown 0 ... seconds “F” Fault shutdown 0 ... seconds ”U“ 5776 774 - 05 max. 60 seconds Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Control Unit Connection Diagram WARNING Disconnect power inside the boiler junction box, before servicing boiler. 5776 774 - 05 Legend A Burner control unit interface VUC 310/base B Flame sensor aA C Vitotronic control unit D Ignition burner inlet damper E Ignition unit gF F Gas valve V1 dG G Gas valve V2 dH H Fan motor with PWM control and feedback 100 A I Boiler temperature sensor 1 3 A J Boiler temperature sensor 2 3 B CAUTION Provide disconnect means and overload protection as required. AC-EMI suppression filter device Secondary boiler water temperature sensor 1 15 A Secondary boiler water temperature sensor 2 15 B Inlet fan pressure switch acA (APS1) Overfire pressure switch acAA (APS2) Inlet gas pressure switch ayA GDW1 Gas pressure switch (outlet pressure at first valve seat) kJ GDW2 R Shut off damper S Burner display and programming unit F1/F2 Fuse K L M N O P Q 163 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Faults Fault display The fault display is activated automatically if the burner control unit switches to a fault state. The most recent fault will then be displayed. The fault LED is also illuminated in case of a non-lockout shutdown or flashes together with the fault code in case of a lockout shutdown. Fault codes are also displayed on the boiler section service display. Fault memory The ten most recent faults are saved and may be called up. The order of scans ranges from the most recent to the earlier fault codes. The fault memory display is terminated automatically if no key is pressed within 20 seconds. Note: If the burner does not start up due to a non-lockout fault without displaying a fault code, the fault memory may be able to indicate the cause. To call up the fault codes, press the following buttons: 1. S longer than 2 seconds “ “ flashes. Fb 2. A Y until “4“ is shown under Service. 3. S “4“ will be displayed under Status. 4. Y/B to scroll through the fault memory display. Service Description A Fault code of the most recent fault (see table from page 165) 1 Display fault codes 2 Detail fault codes 1. Correct the fault. For fault codes and measures, see from page 165. Carry out measures in the indicated order. 3 Clear fault memory 2. Press reset button R for longer than 0.5 seconds The operating display is shown again and the burner control unit is reset. 5. S the selected fault memory display will appear under Status. 6. Y/B to scroll through the fault codes. To clear the fault memory from the operating display, press the following buttons: 1. S longer than 2 seconds “ “ flashes. 2. Y until “4“ is shown under Service. 3. S “4“ will be displayed under Status. 4. Y until “3” is shown under Service. 5. S “1“ is shown under Status and “dEL“under Service. 6. S to confirm the deletion. If deleted successfully, “1“ will be shown under Service, “0“ if it failed. 7. S to change to the operating display. 164 5776 774 - 05 Note: For the fault display on the burner display and control unit, every fault code is stored in the fault memory and the last 10 can be read. Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Fault Codes General process faults Fault display on the programming unit of the burner. Note: Carry out measures in the described order. All fault codes are saved to the fault memory and the last 10 can be called up. 5776 774 - 05 Displayed System Characteristics Fault Code Cause Measures F 80 Burner control unit in a fault state; system cools down; burner control unit locked out Short circuit, boiler water temperature sensor, burner control unit Check lead and dual sensor; replace sensor if required F 81 Burner control unit in a fault state Sensor drift, boiler water temperature sensor, burner control unit Check lead and dual sensor; replace sensor if required F 82 Burner control unit in a fault state; system cools down; burner control unit locked out Short circuit, flue gas temperature sensor (A or B), burner control unit Check lead and sensors (A and B), replace sensor if required F 83 Burner control unit in a fault state Sensor drift, flue gas temperature sensor (A or B), burner control unit Check lead and sensors (A and B), replace sensor if required F 88 Burner control unit in a fault state Lead break, boiler water temperature sensor, burner control unit Check lead and dual sensor; replace sensor if required F 89 Burner control unit in a fault state Lead break, flue gas temperature sensor (A or B), burner control unit Check lead and sensors (A and B), replace sensor if required F b7 Burner control unit in a fault state; system cools down; burner control unit locked out Coding card not inserted in the burner control unit; incorrect or faulty coding card Insert coding card; check coding card; replace if required F b7 Type of coding card Coding card does not match burner control unit Replace coding card or burner control unit Danger Plug-in terminals on the burner control unit are ‘live‘. Only replace the coding card when the power has been isolated from the burner control unit (via the internal power disconnect inside the GW6C). F E1 Gas pressure switch 2, GDW2 activated (closed on pressure rise) 1st gas valve seat leaking/ GDW2. Gas pressure switch 2 activated/burner test firing valve closed. Replace gas valve. F E2 Gas pressure switch 2, GDW2 did not close during control self diagnostics Gas valve does not open, gas valve leaking, gas pressure switch faulty Check cables, check gas pressure switch, replace gas valve F E4 Burner shuts down Multiple detection of under voltage Check the power supply F E5 Burner control unit in a fault state Internal fault of the burner control unit and during test of ionization input Replace burner control unit 165 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Fault Codes (continued) Displayed System Characteristics Fault Code Cause Measures F EE Burner control unit in a fault state Internal error in feedback from Reset burner control unit; replace gas safety valves; output relay burner control unit does not respond F EF Burner control unit in a fault state Internal error in feedback from Reset burner control unit; replace gas safety valves; output relay burner control unit does not respond F F0*1 Emergency operation according to internal default Communication error KM BUS burner control unit Check the KM BUS cable plug for firm seating; check all KM BUS cables F F1 Burner control unit in a fault state; system cools down Flue gas excess temperature; excessive gas throughput Wait until temperature falls below the permissible flue gas temperature. Reset burner control unit. Check water level; check heat exchanger surfaces for contamination; check CO2 setting; set gas throughput according to rated boiler heating output (see connection values page 88). F F2 Burner control unit in a fault state; system cools down Excessive boiler water temperature Wait until temperature falls below the permissible boiler water temperature; reset burner control unit F F3 Ionization flame monitor reports Gas valve leaking (flame Check ionization path; replace coding faulty flame signal during start- present); incorrect coding card card; replace gas valve up or after the post-purge F F4 No flame formation during safety time; ionization flame monitor reports no flame signal Ionization electrode incorrectly Insert plug of ionization electrode; adjusted; ionization electrode check cables; adjust ionization not plugged in. Ground fault electrode (see page 98) of electrode or cable F F4 No flame formation during safety time; ionization flame monitor reports no flame signal Ignition electrode not set correctly; electrodes grounded; ignition unit faulty; burner control unit faulty Adjust ignition electrodes (see page 98); replace ignition unit; replace burner control unit F F4 No flame formation during safety time; ionization flame monitor reports no flame signal Insulation body of ignition or ionization electrode cracked Replace ignition or ionization electrode F F4 Poor start-up characteristics, rotary damper does not close, solenoid valve does not switch Servomotor faulty, servomotor Replace connecting cable; replace connecting cable faulty, servomotor; replace solenoid valve; solenoid valve faulty, burner replace burner control unit control unit output relay faulty F F4 No flame builds during safety time; ionization flame monitor reports no signal Incorrect gas type selected Adjust gas type (see page 66) F F4 No flame builds during safety time; ionization flame monitor reports no signal Gas valve does not open Check the connecting cable; check the gas valve and replace if required 166 5776 774 - 05 *1 Displayed only on the burner control unit. Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Fault Codes (continued) Displayed Fault Code System Characteristics Cause Measures F F4 No flame builds during safety time; ionization flame monitor reports no signal Combustion characteristics not ideal Adjust the burner (see pages 79 and 80, if necessary, also adjust the setting screws when the burner is OFF to be able to start the burner) F F5 Air pressure switch 1, LDW1 Air pressure switch 1, LDW1 shows no air pressure, fan does faulty, incorrectly connected or not operate incorrectly set Replace air pressure switch 1, connect or set correctly F F5 Air pressure switch 1, LDW1 switches off during operation Flue gas back pressure; condensate built up; air pressure switch 1, LDW1 hose faulty; connecting hose leaking Remove flue gas back pressure; check if condensate banked up; reset burner control unit; replace hose F F6 Gas pressure switch 1, GDW1 shows no gas pressure Gas shut-off valve closed; gas pressure switch faulty; multiple problems with gas supply Open gas shut-off valve; check gas flow pressure; replace gas filter if required; reset burner control unit; replace gas valve F F7 Fan pressure is created during the idle state check of air pressure switch 1, LDW1 Wind influence on fan Check flue outlet or (chimney) F F7 Contact of air pressure switch 1, LDW1 not closed in idle state Air pressure switch 1, LDW1 faulty Replace air pressure switch 1, LDW1 F F8 Flame extinguishes during operation Incorrect gas type selected Adjust gas type (see page 66) F F8 Flame extinguishes during operation Burner gauze assembly faulty Check burner gauze assembly; replace if damaged F F8 Flame extinguishes during operation Combustion characteristics not ideal Adjust burner (see pages 79 and 80) F F9 Fan not running; fan speed not reached Fan faulty; cables are faulty or broken Check cables; replace fan if required F F9 Internal fault; fan cannot reach its set value Replace fan or burner control unit F F9 Status duration too long, fan ramp-up Varying fan speed Check cable; replace cable “a-ÖA“ or fan if required F F9 No fan feedback Fan faulty, cable “a-ÖA“ faulty or broken Fan faulty; external power supply to fan not connected or faulty; cable “a-ÖA“ faulty or broken; fan blocked (possibly by a foreign object) F FA Fan runs without demand; burner control unit in a fault state 5776 774 - 05 F Fb Check cable “a-ÖA“, check external power supply; replace cable or fan; remove foreign object Fan has not stopped; cable “a-ÖA“ Wind influence on fan; check flue outlet and fan; replace cable faulty; fan faulty; burner control “a-ÖA“, replace fan; replace burner unit faulty control unit Burner not starting. Combustion Flue gas path or condensate path Check flue gas path or condensate chamber pressure too high; blocked off. Excessive combustion path and clean if required burner control unit in a fault state chamber pressure (air pressure switch 1, LDW2) 167 Burner Control Unit Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Fault Codes (continued) Internal system fault Internal system faults are created if a fault-free program sequence can no longer be ensured. Displayed Fault Code F E5, F EC, F Ed, F Fd, F FF System Characteristics Fault around burner control unit Cause Internal system fault and EMC Measures Reset burner control unit. Replace the burner control unit if the fault persists. Faults Without Fault Display Thermoacoustics/ combustion noise 168 Cause Excessive gas input Measures Adjust gas input in accordance with rated boiler heating output Insufficient or excessive air Condensate build up in flue system Check condensate drain. Incorrect flue outlet Check flue outlet and flue system. Incorrect CO2 settings; insufficient or excessive air Adjust burner in accordance with the details on pages 79 and 80. CO2 content too low Incorrect setting Check that burner has been adjusted and adjust burner in accordance with the details on pages 79 and 80. CO is formed or burner is very sooty Insufficient or excessive air Adjust correctly. Check ventilation of installation room. Insufficient draught in flue system Check flue system. Flame extinguishes during operation Inlet strainer of gas valve contaminated Remove flange and clean strainer. 5776 774 - 05 Fault Combustion fault through pulsation Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists Model No. CA3 3.5 Boiler CA3 4.0 Boiler Serial No. 7769872 7769873 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. CA3 Parts for CA3 3.5/4.0 0001 Vitocrossal 300 CA3 boiler 0002 Vitotronic 300 GW6C control 0003 Boiler enclosure assembly 0004 Other Parts A Rating Plate Other Parts (not illustrated) 0100 Installation Set *1 0150 Technical literature set 5776 774 - 05 *1 For Installation Sets please see separate Parts Lists. 169 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler Serial No. 7769872 7769873 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. 170 5776 774 - 05 CA3 Parts for CA3 3.5/4.0 0001 Side panel, right top front 0002 Side panel, right top rear 0004 Side panel, left top 0006 Side panel, right bottom 0008 Front panel, top 0009 Nameplate “VITOCROSSAL 300” 0010 Nameplate “VIESSMANN” 0011 Panel door 0012 Rear panel 4, bottom 0013 Rear panel 3, bottom 0014 Rear panel 2, top 0015 Cover plate 0016 Rear panel 1, top 0017 Cover plate 0018 Top panel 0020 Insulation blanket 0021 Cable channel 1 0022 Cable channel 2 0024 Cable clasp, 930 mm 0025 Side panel, left front bottom 0027 Side panel, left rear bottom 0028 Cover panel 0029 Filter 0030 Filter mat 0031 Accessory pack for fasteners 0032 Access key for control panel Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler Serial No. 7769872 7769873 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. 5776 774 - 05 CA3 Parts for CA3 3.5/4.0 0001 Boiler section 1.5 MMBH 0002 Boiler section 2.0 MMBH 0003 Fiber rope seal, 25x15x1500 mm 0004 Support bracket 1 0005 Support bracket 2 0006 Plug, 1½” 0007 Fiber rope seal, 18x2100 mm 0008 Sensor well, G½ l=100 mm with clip 0009 Sensor well, G½ l=150 mm with clip 0010 Accessory pack, boiler section 0011 Boiler stand 0012 Cover with tension gasket 0013 Connection pipe for system supply 0014 Gasket, PN10 DN2” 0015 Accessory pack, DN65 for supply 0016 Connection pipe for system return 0017 Accessory pack, DN65 for return 0018 Servomotor, SR230A-5 0019 Flue damper blade, D665N 0020 Connection pipe 1, NG with gaskets 0021 Connection pipe 2, NG with gaskets 0022 Gasket, A46x62x2 Ibenulit 0023 Connection pipe 3, NG with gaskets 0024 Adaptor, R1 1/2 X G2 1/4 0025 Condensate siphon 0026 Cylinder burner, 2.0 MMBH (see separate Parts List) 0027 Cylinder burner, 1.5 MMBH (see separate Parts List) 171 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. CA3 Parts for CA3 5.0/6.0 0001 Vitocrossal 300 CA3 boiler 0002 Vitotronic 300 GW6C control 0003 Boiler enclosure assembly 0004 Other Parts A Rating Plate Other Parts (not illustrated) 0100 Installation Set *1 0150 Technical literature set 172 5776 774 - 05 *1 For Installation Sets please see separate Parts Lists. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists (continued) Model No. CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. 5776 774 - 05 CA3 Parts for CA3 5.0/6.0 0001 Side panel, right top front 0002 Side panel, right top rear 0003 Side panel, right top mid 0004 Side panel, left top 0005 Side panel, left top mid 0006 Side panel, right bottom 0007 Side panel, right mid bottom 0008 Front panel, top 0009 Nameplate “VITOCROSSAL 300” 0010 Nameplate “VIESSMANN” 0011 Panel door 0012 Rear panel 4, bottom 0013 Rear panel 3, bottom 0014 Rear panel 2, top 0015 Cover plate 0016 Rear panel 1, top 0017 Cover plate 0018 Top panel 0019 Top panel mid 0020 Insulation blanket 0021 Cable channel 1 0022 Cable channel 2 0023 Cable channel 3 0024 Cable clasp, 930 mm 0025 Side panel, left front bottom 0026 Side panel, left mid bottom 0027 Side panel, left rear bottom 0028 Cover panel 0029 Filter 0030 Filter mat 0031 Accessory pack for fasteners 0032 Access key for control panel 173 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. 174 5776 774 - 05 CA3 Parts for CA3 5.0/6.0 0001 Boiler section, 1.5 MMBH 0002 Boiler section, 2.0 MMBH 0003 Fiber rope seal, 25x15x1500 mm 0004 Support bracket 1 0005 Support bracket 2 0006 Plug, 1½” 0007 Fiber rope seal, 18x2100 mm 0008 Sensor well, G½ l=100 mm with clip 0009 Sensor well, G½ l=150 mm with clip 0010 Accessory pack, boiler section 0011 Boiler stand 0012 Cover with tension gasket 0013 Connection pipe for system supply 0014 Gasket, PN10 DN2” 0015 Accessory pack, DN65 for supply 0016 Connection pipe for system return 0017 Accessory pack, DN65 for return 0018 Servomotor, SR230A-5 0019 Flue damper blade, D665N 0020 Connection pipe 1, NG with gaskets 0021 Connection pipe 2, NG with gaskets 0022 Gasket, A46x62x2 Ibenulit 0023 Connection pipe 3, NG with gaskets 0024 Adaptor, R1 1/2 X G2 1/4 0025 Condensate siphon 0026 Cylinder burner, 2.0 MMBH (see separate Parts List) 0027 Cylinder burner, 1.5 MMBH (only for 5 MMBH boiler, see separate Parts List) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 5.0 Boiler Serial No. 7769872 7769874 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. 5776 774 - 05 Parts for Burner Assembly, 1.5 MMBH single-fuel 0001 Burner plate, 1.5 MMBH 0002 Burner gasket 0003 Burner chassis 0004 Combustion chamber door refractory 0005 Accessory pack of small burner parts 0006 Burner tube 0007 Gasket for burner tube 0008 Electrodes 0009 Ignition cable 0010 Ignition transformer 0011 Coding plug for burner, 5090 0012 Programming unit assembly 0013 Servomotor, STA 120V 0014 Fan, G3G200 120/1/60 0015 Gasket for fan 0016 Inlet damper 0017 Linkage, M5 0018 Venturi mixing pipe 0019 Gas valve, V4734C1010-1100 0020 Servomotor, STA 120V 0021 Linkage, M5 0022 Flange, 1¼” for gas valve 0023 O-ring, 52x3.5 mm for gas valve 0024 Gas manifold 2, with shut-off 0025 Gasket for triple-electrode 0026 Length compensation harness set 0027 literature for component replacements 0028 Conversion kit, NG 0029 Gasket for fan 0030 Fan adaptor 175 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769872 7769873 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. 176 5776 774 - 05 Parts for Burner Assembly, 2.0 MMBH single-fuel 0001 Burner plate, 2.0 MMBH 0002 Burner gasket 0003 Burner chassis 0004 Combustion chamber door refractory 0005 Accessory pack for small burner parts 0006 Burner tube 0007 Gasket for burner tube 0008 Electrodes 0009 Ignition cable 0010 Ignition transformer 0011 Coding plug (burner, 1.5 MMBH) 5091 0012 Programming unit assembly 0013 Servomotor, STA 120V 0014 Fan, 120/1/60 0015 Gasket (fan) 0016 Inlet damper 0017 Linkage, M5 0018 Venturi mixing pipe 0019 Gas valve, V4734C1010-1100 0020 Servomotor, STA 120V 0021 Linkage, M5 0022 Flange, 1¼” for gas valve 0023 O-ring, 52x3.5 mm for gas valve 0024 Gas manifold 1, with shut-off 1.5 MMBH 0025 Gasket for triple-electrode 0026 Length compensation harness set 0027 instructions for replacement componentry Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769872 7769873 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. 5776 774 - 05 Control Panel 0001 Master-Display 0002 Vitotronic 300, GW6C boiler and system control 0003 Junction Box 177 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. Model No. CA3 3.5 Boiler CA3 4.0 Boiler CA3 5.0 Boiler CA3 6.0 Boiler Serial No. Serial No. 7769872 7769873 7769874 7769875 178 5776 774 - 05 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Master-Display 0001 Control console 0002 Rear housing, Master-Display 0003 Programming unit, Vitotronic 200 HI930 0004 Flat cable, 16-pole 0005 Circuit board, SA168 A10 0006 Harness master power 0007 Harness relay 0008 Sliding covers, left and right Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769872 7769873 7769874 7769875 5776 774 - 05 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Connection Enclosure Assembly 0001 Control unit, module 0002 Cover, motherboard 0003 Extension module for mixing valve 2+3 0004 Motherboard (low voltage, MB200) 0005 Circuit board (CU102-A60.xxx, touch) 0006 Motherboard (120/1/60, MB201) 0007 Circuit board (power supply, SP102) 0008 Circuit board (LON, IU100-B10) 0009 Rear housing, connection enclosure 0010 Control panel, without AHL+FHL, 120/1/60 0011 Switch, 2-pole (on/off) 0012 Fuse holder cover 0013 Fuse holder 0014 Fuse, T6.3A/250V (set of 10) 0015 Sensor #1 (outdoor, NTC) 0016 Sensor #5 (DHW, immersion NTC) 0018 Harness, heating circuit expansion 156/40A 0019 Cable, 1 m shielded 2 x RJ45-Steward 0020 LON connecting cable, 7 m RJ45 0021 LON terminal end resistor (set of 2) 0022 Accessory pack, low voltage plugs 0023 3-Pole plug, male, #20 (set of 3) 0024 4-Pole plug, #52 (set of 3) 0025 3-Pole plug, #156 (set of 3) 0026 3-Pole plug, #40 (set of 3) 0027 3-Pole plug, #50 (set of 3) 0028 Accessory pack (plugs #143,145,146) 0030 Coding plug, 1043:01 0031 Programming unit, Vitotronic 200 HI930 0032 Control sub-base + adaptor + cabling 0033 Connecting cable, emissions text switch 0034 Switch, 1-pole, emissions text switch 0035 Flat cable, 16-pole 179 Parts Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Parts Lists (continued) Model No. CA3 3.5 Boiler CA3 4.0 Boiler CA3 5.0 Boiler CA3 6.0 Boiler Serial No. 7769872 7769873 7769874 7769875 Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. 180 5776 774 - 05 Junction Box Assembly 0001 Vitocom 100 LAN1 without communication module 0002 Disconnect switch 0003 Sealing grommet, M63 0004 Receptacle CA/US 0005 Relay, 110V 0006 Terminal block, 3-pole 0007 Terminal block, PT 2.5 0008 Terminal block, PT 16 0009 Fuse holder 0010 Fuse, 2.0A/250V (set of 10) 0011 Circuit breaker, 16A 0012 Circuit breaker, 10A 0013 Relay, 24-240V 8A SPDT with time delay 0014 Power relay, 120V 30A 0015 Power relay, 120V 10A 0016 Power relay, 120V 10A Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Function Description Boiler Water Temperature Control Brief description H The boiler water temperature is regulated by modulating the burner. H The set boiler water temperature is determined from the following coding: – Set supply temperature of the heating circuits connected to the control unit and the heating circuits connected via the LON BUS – External demand – DHW temperature target H When the DHW tank is heated, the default set boiler water temperature is 36°F (20 K) above the set DHW temperature (adjustable via coding “60” in the “DHW” group). Emissions test function In multi boiler systems, enable the emissions test function on all control units. The following functions are activated: H Burner start H Starting all pumps Note: Only the heating circuit pump is switched ON in the case of boiler section 2/boiler section 3 control. H Mixing valve remains set to control function Function duration < 30 min: The burner operates at 100% output until the temperature limiter in the burner control unit switches off. The burner then cycles, with 100% output, around the value at the temperature limiter. Function duration > 30 min (continuous): Boiler water temperature at max. set value, e.g. 194°F (90°C). The burner is operated in modulating mode. This prevents excessive cycling if emissions testing is carried out over an extended period. Cascade Control Unit Brief description The supply temperature is regulated by starting or stopping the burners or by starting/stopping individual burner stages. H Standalone control (see page 182) H Sequential control (see page 182) 5776 774 - 05 H Subject to system version, a difference is made between the condensing strategy (see page 183) and 2 conventional boiler strategies (see pages 184 and 185). 181 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Cascade Control Unit (continued) Set supply temperature The set supply temperature is determined from the following coding: H Set supply temperature of heating circuit without mixing valve A1 (heating circuit 1) and heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). H Set supply temperature of further consumers. H DHW temperature target. H External demands. Upper control range limits: Maximum system supply temperature limit (coding “37” in the “Cascade” group). Lower control range limits: Minimum system supply temperature limit (coding “36” in the “Cascade” group). Standalone control Note: Vitocrossal 300, type CA3, operate in parallel and with condensing strategy Boilers connected in parallel Boilers connected in series H Without and with supply temperature sensor (see the following table). H Without and with supply temperature sensor H The cascade control specifies the set boiler water temperature for all currently active boilers. Every boiler control unit regulates to the specified set value. H The control strategy is set automatically to conventional boiler strategy 2, coding “3c:2” in the “Cascade” group (see page 127). (see the following table). H The cascade control specifies the set boiler water temperature for all currently active boilers. Every boiler H Condensing strategy (see page 183) control unit regulates to the specified set value. If the H Conventional boiler strategy 1 (see pages 184 and 185) boiler section 1 (condensing boiler) does not achieve the specified set value, it will only act to control H Conventional boiler strategy 2 (see pages 184 and 185) the return temperature of the conventional boiler downstream. The conventional boiler is started late and is also shut down late. The following control strategies are available: With supply temperature sensor Without supply temperature sensor Set coding “3b:1” or “3b:3” in the “Cascade” group. The control deviation is calculated from the set supply temperature and the actual supply temperature to determine the start and shutdown criteria. Set coding “3b:0” or “3b:2” in the “Cascade” group. To determine the start and stop criteria, the control deviation is calculated from the set boiler water temperature and the estimated average actual boiler water temperature of the currently active boilers. Only boilers with open motorized isolation valves are taken into consideration. Sequential control H With supply temperature sensor. H Set coding “3b:4” in the “Cascade” group. H The cascade control unit regulates to the specified set supply temperature by stipulating the output for each individual boiler. The boiler section 1 can be operated in modulating mode. All other boilers are operated in two stages via a specified output (incl. modulating burners). 182 5776 774 - 05 H The control strategy is set automatically to conventional boiler strategy 2, coding “3c:2” in the “Cascade”group (see page 127). Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Function Description Cascade Control Unit (continued) Control strategies Condensing strategy Benefit: Optimal utilization of the condensing effect and long burner run-times. Set coding “3C:0“ in the “Cascade” group. It is the aim of the condensing strategy to operate as many boilers as possible at the lowest output level. Starting Shutdown Starting criterion: An output statement causes the boilers to start (Coding “3d:1” in the “Cascade” group). An additional boiler will start if the current heat demand can be covered by the currently active boilers plus the next boiler in the boiler sequence. Shutdown criterion: The boilers are shut down via a shutdown integral. When the shutdown integral exceeds a limit set at coding “46” in the “Cascade” group, the shutdown criterion is met and the boiler started last will be shut down. 5776 774 - 05 Example (coding “3C:0” in the “Cascade” group) Two-boiler system with modulating burners: Boiler 1: 100% rated heating output (base load set to 33%) Boiler 2: 100% rated heating output (base load set to 33%) 183 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Cascade Control Unit (continued) Conventional boiler strategies Conventional boiler strategy 1 Conventional boiler strategy 2 Benefit The number of boilers in operation is the lowest possible. Set coding “3C:1“ in the “Cascade” group. It is preferable to operate conventional boilers at their upper output range, to reliably prevent formation of condensate when return temperatures are low. An additional boiler will only be started if the maximum output of all currently active burners is insufficient to achieve the supply temperature set value. A boiler will be shut down when the remaining boilers can achieve the required output on their own. Long burner run times. Set coding “3C:2“ in the “Cascade” group (factory set condition). An additional boiler will only be started if the maximum output of all currently active burners is insufficient to achieve the supply temperature set value. A boiler will be shut down if the burners were ramped down to their minimum output because of a major negative control deviation and the output is still too high. Starting criterion The boilers are started via a starting integral. The next boiler in the boiler sequence will be started if the value set in coding ”45” in the “Cascade” group is exceeded. The boilers are started via a starting integral. The next boiler in the boiler sequence will be started if the value set in coding ”45” in the “Cascade” group is exceeded. Shutdown criterion A reduction in output causes the boilers to shut down (Coding “3d:1“ in the “Cascade“ group). A boiler will be shut down when the currently required output can be achieved without the most recently started boiler. The boilers are shut down via a shutdown integral. When the shutdown integral exceeds a limit set at coding “46” in the “Cascade” group, the shutdown criterion is met and the boiler started last will be shut down. 184 5776 774 - 05 Examples Two-boiler system with modulating burners: Boiler 1: 100% rated heating output (base load set to 33%) Boiler 2: 100% rated heating output (base load set to 33%) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Function Description Cascade Control Unit (continued) Conventional boiler strategy 1 (coding “3c:1” in the “Cascade” group) Starting Shutdown Conventional boiler strategy 2 (coding “3c:2” in the “Cascade” group) 5776 774 - 05 Starting Shutdown 185 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Heating Circuit Control Unit Brief description H The control unit features control circuits for one heating circuit without mixing valve A1 (heating circuit 1) and two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3). H The set supply temperature of each boiler is determined from the following coding: – Outdoor temperature – Set room temperature – Operating mode – Heating curve slope and shift H The supply temperature of the heating circuit without mixing valve corresponds to the common system supply temperature. H The supply temperature of the heating circuits with mixing valve is regulated by the stepped opening or closing of the mixing valves. The mixing valve motor control changes the actuating and pause times subject to the control differential (control deviation). Functions The heating circuit without mixing valve is subject to the boiler water temperature and its control range limits. The heating circuit pump is the only actuator. The supply temperature of the heating circuits with mixing valve is captured by the supply temperature sensor of the relevant heating circuit. H Upper control limit: Electronic maximum supply temperature limit coding address “c6” in the “Heating circuit...” group. H Lower control range limit: Electronic minimum supply temperature limit coding address “c5” in the “Heating circuit...” group. Time program The control unit switches over according to the time program. In the “Heating and DHW” operating program, the control unit switches between “Central heating with standard room temperature” and “Central heating with reduced room temperature”. Every operating mode has its own set level. 4 time phases per day can be selected. 186 Outdoor temperature A heating curve must be set for matching the control unit to the building and the heating system. The heating curve characteristics determine the set boiler water temperature subject to outdoor temperature. The control unit uses an average outdoor temperature. This comprises the actual and the adjusted outdoor temperature. Room temperature In conjunction with a remote control and room temperature hook-up (coding “b0” in the “Heating circuit...”) group: Compared with the outdoor temperature, the room temperature has a greater influence on the set boiler water temperature (changed at coding “b2” in the “Heating circuit...” group). In conjunction with heating circuits with mixing valve: For control differentials (actual value deviation) above 4°F (2 K) room temperature, the influence can be increased further (coding “b6” in the “Heating circuit...” group): H Quick heat-up The set room temperature must be raised by at least 4°F (2 K) by the following measures: – Enabling comfort mode – Changing from central heating with reduced temperature to central heating with standard temperature – Start optimization (coding “b7” in the “Heating circuit...” group) Quick heat-up will stop when the set room temperature has been reached. H Quick setback The set room temperature must be reduced by at least 4°F (2 K) by the following measures: – Activating economy mode – Changing from central heating with standard temperature to central heating with reduced temperature – Shutdown time optimization (coding address “c1” in the “Heating circuit...” group) Quick setback ends when the set room temperature has been reached. 5776 774 - 05 Only for single boiler and cascade control units Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Function Description Heating Circuit Control Unit (continued) DHW temperature Priority control H With priority control: (coding address “a2:2” in the “Heating circuit...” group): The set supply temperature will be adjusted to 32°F (0°C) during tank heating. The mixing valve closes and the heating circuit pump is switched off. H Without priority control: The heating circuit control unit continues to operate with the same set value. H With modulating priority control in conjunction with heating circuits with mixing valve: The heating circuit pump remains switched on. During tank heating the set supply temperature of the heating circuit will be reduced until the set boiler water temperature has been reached. The set supply temperature is determined from the following coding: – Outdoor temperature – Differential between the set and the actual boiler water temperature – Heating curve slope and shift – Set coding “a2” in the “Heating circuit...” group System dynamics The mixing valve control characteristics can be influenced at coding “c4” in the “Heating circuit...” group. Central control Coding “7a” in the “General” group enables you to program central control to one heating circuit. The operating and holiday program then applies to all additional heating circuits of the system. For these heating circuits, when the operating and holiday program is enabled,“Central control” is displayed. Any holiday programs that may have been set will be deleted. Party and economy modes cannot be enabled on all control units. Frost protection The supply temperature is held in accordance with the heating curve for the reduced set room temperature, but at least at 50°F (10°C). A variable frost limit can be set in line with coding address “a3” in the “Heating circuit...” group. Heating circuit pump logic – Economy circuits The heating circuit pump is switched OFF [set supply temperature set to 32°F (0°C)] if one of the following criteria is met: H The outdoor temperature selected in coding “a5” in the “Heating circuit...” group exceeds the set value. H The adjusted outdoor temperature exceeds the value set in coding“a6” in the “Heating circuit...” group. H The mixing valve has been attempting to close for more than 12 min. (mixing valve economy function, coding “a7” in the “Heating circuit...” group). H The pump idle time selected in coding “a9” in the “Heating circuit ...” group is reached. Requirements: – There is no risk of frost. – Coding “b0” in the “Heating circuit...” group must be set to 0. Note: If, during the pump idle time, the system is switched to heating mode or the set room temperature is increased, the heating circuit pump is switched ON,even if the time has not yet elapsed. 5776 774 - 05 H The actual room temperature exceeds the value set in coding “b5” in the “Heating circuit ...” group. 187 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Heating Circuit Control Unit (continued) Supply temperature control single boiler control unit Differential temperature: The differential temperature can be set at coding “9f” in the “General”group, factory set condition: 15°F (8 K). The differential temperature is the minimum value by which the boiler water temperature should be higher than the highest currently required supply temperature of the heating circuit with mixing valve. H System with only one heating circuit with mixing valve: The set boiler water temperature will be automatically regulated to 15°F (8 K) above the set supply temperature. Legend A Maximum supply temperature limit (coding “37” in the “Cascade” group) B Slope = 1.8 for heating circuit without mixing valve C Slope = 1.2 for heating circuit with mixing valve D Common supply temperature [at a differential temperature = 15°F (8 K)] E Lower common supply temperature 188 Supply temperature control cascade control unit Differential temperature: The differential temperature can be set at coding “9f” in the “General” group, factory set condition 15°F (8 K). The differential temperature is the value by which the common supply temperature should be higher than the highest currently required supply temperature of the heating circuit with mixing valve. H System with only one heating circuit with mixing valve: The common set supply temperature is regulated automatically to 15°F (8 K) above the set supply temperature of the heating circuit with mixing valve. H System with heating circuit without mixing valve and heating circuits with mixing valve: The common set supply temperature operates in accordance with its own heating curve. The differential temperature of 15°F (8 K) towards the set supply temperature of the heating circuits with mixing valve is set at the factory. 5776 774 - 05 Supply temperature Legend A Max. boiler water temperature B Slope = 1.8 for heating circuit without mixing valve C Slope = 1.2 for heating circuit with mixing valve D Boiler water temperature [with a differential temperature = 15°F (8 K)] E Lower boiler water temperature, defaulted by the boiler coding card H System with heating circuit without mixing valve and heating circuit with mixing valve: The set boiler water temperature operates in accordance with its own heating curve. The differential temperature of 15°F (8 K) towards the set supply temperature is set at the factory. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Heating Circuit Control Unit Function Description (continued) Example using the settings in the factory set condition Legend A Heating curve for operation with standard room temperature B Heating curve for operation with reduced room temperature Example using the settings in the factory set condition Raising the reduced room temperature During operation with reduced room temperature, the reduced set room temperature can be automatically raised subject to the outdoor temperature. The temperature is raised in accordance with the selected heating curve, but no higher than the set standard room temperature. The outdoor temperature limits for the start and end of temperature raising can be set in coding “f8” and “f9” in the “Heating circuit...” group. Reducing the heat-up time During the transition from operation with reduced room temperature to operation with standard room temperature, the boiler water or supply temperature will be raised in accordance with the selected heating curve. The boiler water or supply temperature increase can be automatically raised. The value and duration for the additional raising of the boiler water temperature or set supply temperature can be set in coding “fa” and “fb” in the “Heating circuit...” group. Control sequence Mixing valve circuit The mixing valve motor will not be switched within the “neutral zone” ±2°F (±1 K). Supply temperature drops (Set value -2°F (–1 K) The mixing valve motor receives the signal “mixing valve open”. The signal duration lengthens with an increasing control differential. The duration of pauses reduces with an increasing control differential. Supply temperature rises (set value +2°F (+1 K) The mixing valve motor receives the signal “mixing valve close”. The signal duration lengthens with an increasing control differential. The duration of pauses reduces with an increasing control differential. 5776 774 - 05 Legend A Start of operation with standard room temperature B Set boiler water or supply temperature in accordance with the selected heating curve C Set boiler water or supply temperature in accordance with coding “fa”: 122°F (50°C) + 20% = 146°F (60°C) D Duration of operation with higher boiler water or set supply temperature in accordance with coding “fb”: 60 min 189 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service DHW Tank Temperature Control H The tank temperature control is a constant temperature control function. This is achieved by starting and stopping the DHW pump. The switching differential is ±5°F (±2.5 K). H When the DHW tank is heated, a set supply temperature is specified that is 36°F (20 K) higher than the set DHW temperature (adjustable at coding “60” in the “DHW” group). Functions Time program An automatic or an individual time program may be selected for DHW pump and the DHW recirculation pump. Compared with the heating circuit heatup phase, DHW heating starts 30 min earlier in automatic mode. The individual time program enables up to 4 time phases per day to be set for DHW pump and the DHW recirculation pump for every day of the week. All tank heating sequences will be completed independently of the time program. In conjunction with coding “7f” in the “General” group H Detached house Coding “7f:1”: – Automatic mode The heating times for heating circuit 1 are applied to systems with two or three heating circuits. – Individual time program The time phases for DHW pump and the DHW recirculation pump have the same effect on all heating circuits. H Apartment building Coding “7f:0”: – Automatic mode For systems with two or three heating circuits, the heating times for the respective heating circuit will be applied. – Individual time program The time phases for DHW pump and the DHW recirculation pump can be adjusted individually for each heating circuit. 190 Priority control H With priority control: (coding “a2:2” in the “Heating circuit...” group): The set supply temperature will be adjusted to 32°F (0°C) during tank heating. The mixing valve closes and the heating circuit pump is switched off. H Without priority control: The heating circuit control unit continues to operate with the same set value. H With modulating priority control in conjunction with heating circuits with mixing valve: The heating circuit pump remains switched on. During tank heating the set supply temperature of the heating circuit will be reduced until the set boiler water temperature has been reached. The set supply temperature is determined from the following coding: – Outdoor temperature – Differential between the set and the actual boiler water temperature – Heating curve slope and shift – Set coding “a2” in the “Heating circuit...” group Frost protection The DHW tank will be heated to 68°F (20°C) if the DHW temperature falls below 41°F (5°C). Forth phase heating function (auxiliary function for DHW heating) This function is activated by providing a second set DHW temperature at coding “58” in the “DHW” group and activating the fourth DHW phase for DHW heating. Set DHW temperature The set DHW temperature can be adjusted between 50 and 140°F (10 and 60°C). Coding “56” in the “DHW” group enables the set range to be extended to 203°F (95°C). Coding “66” in the “DHW” group enables the set value of the programming unit and/or remote control Vitotrol 300 to be assigned. DHW recirculation pump This delivers hot water to the draw-off points at adjustable times. Four time phases can be selected at the control unit for every day. 5776 774 - 05 Brief description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service DHW Tank Temperature Control (continued) Auxiliary circuits DHW heating in conjunction with the heating circuits can be disabled or enabled by changing over the operating program (see coding “d5” in the “Heating circuit...” group). System with tank loading system The above functions also apply in conjunction with tank loading systems. Set the following coding: “55:3” in the “DHW” group; “4c:1”, “4e:2” in the “General” group. The DHW tank is only reheated by the boiler if the temperature falls below this value. System with solar control unit A third set DHW temperature can be assigned at coding “67” in the “DHW” group. The DHW tank is only reheated by the boiler if the temperature falls below this value. Controlled sequence single boiler control Coding “55:0” in the “DHW” group; tank heating The DHW tank goes cold [set value -5°F (–2.5 K), adjustable via coding “59”]: H The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). H Pump on: – Starting the DHW pump is subject to boiler water temperature (coding “61:0”). The DHW pump starts when the boiler water temperature is 14°F (7 K) higher than the DHW temperature. – Starting the DHW pump for tank heating immediately (coding “61:1”). The DHW tank is hot [set value +5°F (+2.5 K)]: H The set boiler water temperature is reset to the weather-compensated set value. H Pump delay off: The DHW pump runs on after tank heating until one of the following criteria is met: – The differential between the boiler water temperature and the DHW temperature is less than 13°F (7 K). – The weather-compensated set boiler water temperature has been reached. – The set DHW temperature is exceeded by 10°F (5 K). – The set max. delay off time is reached (coding “62”). 5776 774 - 05 H Without pump delay off (coding “62:0”). Function Description Coding “55:1” in the “DHW” group; adaptive tank heating With adaptive tank heating, the speed of the temperature rise during DHW heating is taken into account. The DHW tank goes cold [set value -5°F (-2.5 K), adjustable via coding “59”]: H The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). H Pump on: – Starting the DHW pump is subject to boiler water temperature (coding “61:0”): The DHW pump starts when the boiler water temperature is 13°F (7 K) higher than the DHW temperature. – Starting the DHW pump immediately (coding “61:1”). The DHW tank is hot: H The control unit checks whether the boiler will still be required to supply heating energy after the tank has been heated up or whether residual boiler heat should be transferred to the DHW tank. Accordingly, the control unit determines the burner and DHW pump stop times to prevent the set DHW temperature being substantially exceeded after the tank has been heated up. Coding “55:2” in the “DHW” group; tank temperature control with 2 tank temperature sensors Tank temperature sensor 1 enables the DHW pump and is evaluated for stop conditions during the pump delay off time. Tank temperature sensor 2: Tank heating will start early if a lot of hot water is drawn off. Tank heating will terminate early if no hot water is drawn off. DHW tank goes cold: H Set value -5°F (–2.5 K), change at coding “59” or H Actual DHW temperature at sensor 2 < set DHW temperature x factor for start time (adjustment at coding “69”) The DHW tank is hot: H set value 5°F (2.5 K) and H Actual DHW temperature at sensor 2 > set DHW temperature x factor for stop time (adjustment at coding “68”) 191 Function Description (continued) Coding “55:3” in the “DHW” group; tank temperature control tank loading system The DHW tank goes cold [set value -5°F (–2.5 K); change at coding “59”]: H The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). H The primary pump in the tank loading system starts. H The 3-way mixing valve opens and then regulates to the specified set value. H The DHW pump cycles (briefly switches on and off) until the set supply temperature has been reached [set DHW temperature +10°F (+5 K)]. Then it runs constantly. If, during heating, the actual value falls below the required set temperature, the DHW pump will temporarily cycle again. The DHW tank is hot: H Tank temperature sensor 1: Actual value ≥ set value and Tank temperature sensor 2: Actual value > set value -3°F (–1.5 K): H The set boiler water temperature is reset to the weather-compensated set value. H The DHW pump stops immediately when the 3-way mixing valve is fully opened. or H The DHW pump stops after expiry of the delay off time that is selected at coding “62”. 192 Controlled sequence cascade control The following coding in the “DHW” group influence the controlled sequence. Tank heating (coding “55:0”) The DHW tank goes cold [set value -5°F (–2.5 K), adjustable via coding “59”]: H The common set supply temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). The DHW tank is hot [set value +5°F (+2.5 K)]: H The common set supply temperature is returned to the set weather-compensated value. H With pump delay off: The DHW pump runs on after tank heating until one of the following criteria is met: – The set DHW temperature is exceeded by 9°F (5 K). – The set max. delay off time is reached (coding “62”). H Without pump delay off (coding “62:0”). Adaptive storage tank heating enabled (coding “55:1”) With adaptive tank heating, the speed of the temperature rise during DHW heating is taken into account. The DHW tank goes cold [set value -5°F (–2.5 K), adjustable via coding “59”]: H The common set supply temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). The DHW tank is hot: H The control unit checks whether the boiler will still be required to supply heating energy after the tank has been heated up or whether residual boiler heat should be transferred to the DHW tank. Accordingly, the control unit determines the burner and circulation pump stop times to prevent the set DHW temperature being substantially exceeded after the tank has been heated up. 5776 774 - 05 DHW Tank Temperature Control Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service DHW Tank Temperature Control (continued) Storage tank temperature control with 2 temperature sensors (coding “55:2”) Tank temperature sensor 1 enables the DHW pump for tank heating and is evaluated for stop conditions during the pump delay off time. Tank temperature sensor 2: Tank heating will start early if a lot of hot water is drawn off. Tank heating will terminate early if no hot water is drawn off. DHW tank goes cold: H Set value -5°F (–2.5 K), adjustable via coding “59” or H Actual DHW temperature at sensor 2 < set DHW temperature x factor for start time (adjustment at coding “69”) The DHW tank is hot: H Set value +5°F (+2.5 K) and H Actual DHW temperature at sensor 2 > set DHW temperature x factor for stop time (adjustment at coding “68”) Function Description Coding “55:3” in the “DHW” group; tank temperature control tank loading system The DHW tank goes cold [set value -5°F (–2.5 K), adjustable via coding “59”]: H The common set supply temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”). H The primary pump in the tank loading system starts. H The 3-way mixing valve opens and then regulates to the specified set value. H The DHW pump cycles (briefly switches on and off) until the set supply temperature has been reached [set DHW temperature +9°F (+5 K)]. Then it runs constantly. If, during heating, the actual value falls below the required set temperature, the circulation pump for tank heating will temporarily cycle again. The DHW tank is hot: H Tank temperature sensor 1: Actual value ≥ set value and Tank temperature sensor 2: Actual value > set value -3°F (-1.5 K): H The common set supply temperature is returned to the set weather-compensated value. 5776 774 - 05 H The DHW pump stops immediately when the 3-way mixing valve is fully opened. or The DHW pump stops after expiry of the delay off time that is selected at coding “62”. 193 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Sensors Tank, supply and room temperature sensors IMPORTANT The supply temperature sensor can be used as a surface contact temperature sensor or immersion temperature sensor. Refer to the Vitotrol 300 Installation and Service Instructions Viessmann NTC 10 kΩ (blue ID label) Tank, supply and room temperature sensor Note: The supply temperature sensor can be used as a contact or immersion temperature sensor. Resistance in k ohms Refer to the Installation and service instructions for Vitotrol 300. 1. Pull corresponding plug. 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, check the installation and replace the sensor if required. Temperature Viessmann NTC 10 kΩ Outdoor temperature sensor 1. Pull plug !. Resistance in k ohms 2. Check the sensor resistance across plug terminals “1” and “2” and compare with the curve. 3. If the results are very different from the curve, disconnect the wires from the sensor and repeat the test on the sensor. 4. Depending on the result, replace the lead or the outdoor temperature sensor. 194 5776 774 - 05 Temperature Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Air Pressure Switches Fan pressure monitoring function (LDW1) The switching threshold of the air pressure switch 1, (LDW1) is monitored in all fan start-up phases and tested during modulating operation of the burner. This way a minimum amount of pre-aeration will be ensured, among other things. The air pressure switch A triggers a fault shutdown on the burner control unit in the following situations: If the system cold-state checkup is not successful after approx. 5 minutes, If the air pressure during the pre-aeration phase is outside of the permissible range (tolerance period approx. 5 minutes), If the air pressure switch fails during normal operation or the air pressure is outside of the permissible range. A fault shutdown is registered on the burner control unit display (see page 164) with fault indicators “F F5” and “F F7”. The fault shutdown can be released by pressing the reset button R. Rated heating output Setting value LDW1 1500 MBTU 0.8“w.c. (2 mbar) 2000 MBTU 0.8“w.c. (2 mbar) Combustion chamber pressure monitoring function (LDW2) In order to monitor the pressure in the combustion chamber, the switching threshold of the air pressure switch 2 (LDW2) is monitored in all operational phases (with the exception of safety and stabilization times). The air pressure monitor B will generate a fault shutdown at the burner control unit in the following situations: If the combustion chamber pressure lies outside of the permissible range after two attempts during the preaeration phase, normal operation, or the post-purge phase. The fault shutdown is registered with the fault indicator “F Fb” in the burner control unit display. The fault shutdown can be released by pressing the reset button R. 5776 774 - 05 Rated heating output Setting value LDW1 1500 MBTU 3.6”w.c. (9 mbar) 2000 MBTU 4.0”w.c. (10 mbar) 195 Function Description Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Burner Parts 196 G H K L M N Gas pressure monitor Rotary slide valve with servomotor Venturi mixing tube Gas fan Burner tube Ignition electrodes 5776 774 - 05 Legend A Burner chassis B Air pressure monitor 1 C Air pressure monitor 2 D Burner control unit E Combination gas valve F Gas connector pipe Accessory Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Extension EA1 Accessory (optional) Duration of the heating program changeover H Contact constantly closed: The changeover is active as long as the contact is closed. H Contact only closed briefly via pushbutton: The changeover is enabled for the time selected in coding address “f2” in the “Heating circuit...” group. DHW recirculation pump runtime for brief operation The DHW recirculation pump can be started outside the times when it is enabled according to the time program. Digital data inputs DE1 to DE3 Functions: H External heating program changeover, separate for heating circuits 1 to 3 H External blocking H External blocking with fault message input H External demand with minimum boiler water temperature H Fault message input H Brief operation of the DHW recirculation pump Input function assignment Select the input functions by means of the following codes in the “General” group at the boiler control unit: H DE1: Coding address “5d” H DE2: Coding address “5e” H DE3: Coding address “5f” Assigning the heating program changeover function to the heating circuits The allocation of the heating program changeover to the relevant heating circuit is selected via coding address “d8” in the “Heating circuit...” group: H Code “d8:1”: Changeover via input DE1 H Code “d8:2”: Changeover via input DE2 H Code “d8:3”: Changeover via input DE3 5776 774 - 05 The effect of the heating program changeover is selected via coding address “d5” in the “Heating circuit...” group. The DHW recirculation pump is started by closing the contact at DE1, DE2 or DE3 by means of a pushbutton. The runtime is adjusted via coding address “3d” in the “General” group. Analog input 0–10V The 0–10V hook-up provides an additional set boiler water temperature: 0–1V Is taken as “no default for set boiler water temperature”. Note: Ensure DC separation between the LV output and the ground conductor of the onsite voltage source. Coding address “1e” in the “General” group: H “1e:0” ≙ temperature demand adjustable in the range from 32 to 212°F (0 to 100°C) 1V ≙ 50°F (10°C) set value change 10V ≙ 212°F (100°C) set value change H “1e:1” ≙ temperature demand adjustable in the range from 86 to 248°F (30 to 120°C) 1V ≙ 86°F (30°C) set value change 10V ≙ 248°F (120°C) set value change Output aBJ Connection of a central fault messaging facility or signalling reduced mode (reduction of the heating circuit pump speed). Select the function of output aBJ via coding address “5c” in the “General” group. Refer to the EA1 module Installation Instructions 197 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Safety and Liability Operational reliability Note: The Vitocom 100 establishes communication via the internet between the connected Vitotronic control unit and the user interfaces, e.g. Vitodata 100 or Vitotrol app. Technical details on the control functions and the messages transferred should be taken from the installation and service instructions for the Vitotronic control unit or the heat source. The respective range of functions will only be available if the following conditions are met: H The Vitotronic control units and the Vitocom 100 must be connected and configured correctly. H The Vitocom 100 is connected to the internet via a DSL router. H Internet access must be available at all times. H User registration has been carried out (see page 208). H In order to send messages via the Vitodata 100, the recipients must be set up correctly on the Vitodata server. H To ensure that messages can still be transferred during mains failure, we recommend connecting the Vitocom 100 and DSL router to the power supply via a UPS. Liability Viessmann accepts no liability for loss of profit, unattained savings, or other direct or indirect consequential losses resulting from the use of the Vitocom or the software, nor for losses resulting from inappropriate use. The Viessmann General Terms and Conditions apply; these are listed in the relevant current Viessmann price list. Viessmann accepts no liability for SMS and e-mail services provided by network operators. The terms and conditions of the relevant network operators therefore apply. Heating system H The Vitocom 100, type LAN1 can be used with Vitotronic control unit, with or without heating circuits downstream. H The max. number of devices (LON participants) comprising of cascade control boiler(s) and heating circuit control units is 30. Supported heat sources For an up to date list of supported heat sources, see Online help Vitodata 100 (www.vitodata100.viessmann. com). 198 5776 774 - 05 Note: - The heating system and the functionality of the message paths must be checked at regular intervals. - For further improvement of the operational reliability of the heating system, we recommend implementing supplementary measures, e.g. frost protection or monitoring for water damage. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocom 100, LAN 1 System Requirements IP network DSL router with a free LAN connection (on site). H Internet connection with “flat rate” (flat rate tariff independent of time and data volume) with high level of availability, i.e. the Vitocom 100 is permanently connected with the Vitodata server. H Have dynamic IP addressing (DHCP) in the network (LAN) checked on site, and if required set up, by an IT expert prior to commissioning. H Determine the routing and safety parameters in the IP network (LAN) so that port 80 and port 443 are approved for direct outgoing connections. Prior to commissioning have this checked on site by an IT expert and, if necessary, set up. Note: During operation, the Vitocom 100 establishes a secure internet connection to the Vitodata server. The Vitocom 100 cannot be connected to any other servers. User account on the Vitodata server Operating a Vitocom 100 and using the Vitotrol app require a valid user account on the Vitodata server. Registration is possible either using the Vitodata 100 user interface or the Vitotrol app (see page 208). Control device for the Vitotrol app Recommended mobile end device (for operating system, see App Store or Play Store): H iPhone iOS Version7 or higher H iPad2 or higher H iPod Touch with retina display H Terminal devices using Android Version 4 or higher Control device for the Vitodata 100 user interface Computer equipped with the following: H Functionality tested with web browser - Microsoft Internet Explorer, Version 8, 9, 10 and 11 - Firefox, Version 35 - For mobile terminal devices: Safari H ‘Active’ internet connection Message designations H Terminal device for receiving mail, e.g. computer H Mobile phone for receiving SMS (only with internet service “Vitodata 100 fault management”). 5776 774 - 05 H Fax for receiving messages (only with internet service “Vitodata 100 fault management”). 199 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Operation with the Vitotrol App For remote control of Viessmann heating systems with Vitotronic control units via IP networks. Functions Vitotrol app control functions H Setting set temperatures. H Setting operating programs. H Scanning operating conditions and temperatures Note: The Vitotrol app only allows the user to access one system at a time using a single end device. For further information on the Vitotrol app, see www.viessmann.de/vitotrolapp. Legend A Heat source with control unit B LON cable C Vitocom 100 D IP network (on site) E DSL router (on site) F Secure internet connection to the Vitodata server G Vitodata server H Mobile end device (see page 199) with the Vitotrol app: H Remote control of the heating system. H Message retrieval. Forwarding messages Pending messages in the heating system, e.g. sensor or burner faults are transferred via LON to the Vitocom 100. The Vitocom 100 transmits these messages to the Vitodata server. The Vitotrol app scans the status of the heating system cyclically and displays the messages. Note: Heating system messages are only displayed if the Vitotrol app is enabled on the mobile end device. Content of messages H Notification type H Message code 200 5776 774 - 05 H Message text Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Operation with Vitodata 100 User Interface For remote monitoring and control of Viessmann heating systems with Vitotronic control units via IP networks. Functions Vitodata 100 control functions H Setting set temperature values, heating curve slope and shift. H Setting operating programs, holiday programs and switching times. H Setting party or economy mode. H Scanning operating conditions and temperatures Legend A Heat source with control unit (see page 4) B LON cable C Vitocom 100 D IP network (on site) E DSL router (on site) F Secure internet connection to the Vitodata server G Vitodata server, registration and log-in via www. vitodata100.viessmann.com H Computer: H Remote control of the heating system via the Vitodata 100 user interface H Receipt of messages via email K Fax for receiving messages (only with internet service “Vitodata 100 fault management”) L Mobile phone for receiving messages via SMS (only with internet service “Vitodata 100 fault management”) Forwarding messages Pending messages in the heating system, e.g. sensor or burner faults, are transferred via LON to the Vitocom 100. The Vitocom 100 transmits these messages to the Vitodata server. The messages can be displayed on the Vitodata 100 user interface. If recipients (email, fax or SMS) are stored on the Vitodata server, the messages are automatically forwarded to these recipients. Note: The Vitodata fault management internet service is required for forwarding messages by fax or SMS (Vitocom 100 standard delivery, free of charge for 3 years). Content of messages H Date and time H System description H Message text H Fault code H System status Heat source installation and service instructions Checking Network Settings Have the following settings on the DSL router checked, and if necessary adjusted, by an IT expert: H Dynamic IP addressing (DHCP) must e enabled. 5776 774 - 05 H Port 80 and port 443 must be approved for outgoing connections. 201 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Sequence Overview Sequence Responsibility Installation 1 Check system requirements. Heating contractor/IT expert 6 Connect Vitocom 100 to network (LAN). Heating contractor/IT expert 8 Power supply Heating contractor Commissioning 9 Switch on Vitocom 100. Heating contractor 10 Check LON connection to the Vitotronic control unit. Heating contractor 11 Register user and set up heating system. Heating contractor/system user H Operation with the Vitotrol app H Operation with the Vitodata 100 user interface 12 Trigger heating system fault and check reporting. Heating contractor Overview of Connections 202 5776 774 - 05 ! Plug-in power supply unit connection, 5 V–, internal +, external –, min. .6 A § Not Used $ RJ 45 connector for LAN connection cable to DSL router (see page 203 and “Explanation of displays” see page 204) ) LON terminator, is enabled in the factory set condition (position of switch left, do not adjust) aÖ RJ 45 connector for LON connection cable (red) to the Vitotronic control unit (see communication module installation instructions) Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocom 100, LAN 1 Connecting to the Network (LAN) 1. Plug LAN connecting cable into LAN connection $ of the Vitocom 100. 2. Plug the free end of the LAN connecting cable into a LAN connection on the DSL router or at the on-site network installation. DSL router documentation (on site) Display and Control Elements Without cover 5776 774 - 05 Legend A Rating plate "T1" Maintenance button (see page 209) "T2" No function "T3" LON key, only when integrating the Vitocom 100 into a BMS (send service PIN). "T4" Reset button (see page 209) "1" LON service indicator (green LED) "2" No function "3" IP connection status (green and yellow LED) "4" Operating status display (green and red LED) "5" Display for data transfer service interface (green LED) 203 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Display and Control Elements (continued) With cover “T1” Maintenance button (see page 203) “3” IP connection status (green and yellow LED) “4” Operating status display (green and red LED) Explanation of displays LON service indicator “1” Flashes green LON participant check successful (see page 206). IP State of connection “3” Flashes yellow/illuminates yellow Establishing a connection (see page 205), or connection fault (see page 210), to the DSL router (DHCP server), internet or vitodata server. Illuminates green Connection to the Vitodata server established. Flashes green Data transfer between the Vitocom 100 and Vitodata server enabled. Operating status display “4” 204 Enabling maintenance (see page 209). Flashes red Heating system fault. Flashes green longer than 3 min Fault when initializing the Vitocom 100 (see page 210). Illuminates green “Standard mode”, no heating system or Vitocom 100 fault. Flashes green The Vitocom 100 will initialize after the power supply unit is lugged in or the reset button is pressed. Flashes green quickly Software update is being installed. The device must not be isolated from the mains. 5776 774 - 05 Illuminates red Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocom 100, LAN 1 Switching on the Vitocom 100 Note: If the connection values of the power supply unit do not match the power consumption of the Vitocom 100, this can lead to interruption of operations and damage to the power supply or the Vitocom 100. Only use the power supply unit supplied. 1. Plug LV side of the plug-in power supply unit into terminal ! (see page 202) of the Vitocom 100. 2. Plug power supply unit into standard 120V~ socket. Vitocom 100 is initialized (see "Initialization"). Initialization When the Vitocom 100 is initializing, the following processes run in sequence: 1. The Vitocom 100 starts and loads the internal operating software The operating status display “4” (see page 204) flashes green after max. 40 sec. After a few minutes, operating status display “4” illuminates green. 2. Connect with the Vitodata server IP connection status display “3” (see page 204) shows the procedure for establishing the connection: H Flashes yellow slowly: H The Vitocom 100 is integrated into the on-site IP network (obtain IP address of DHCP server). H Flashes yellow quickly: H Internet connection is being established. H Illuminates yellow: H Connection to the Vitodata server is being established. H Illuminates green: H Secure connection to the Vitodata server is established. 3. Connect with the Vitotronic control unit via LON The Vitocom 100 creates a list of all LON participants. Note: It may take several minutes to establish the connection via LON. Initialization successful The Vitocom 100 is ready for operation. The following LED indicators illuminate green: operating status display “4” and IP connection status “3”. 5776 774 - 05 Initialization not successful If a fault occurs during initialization, this is indicated by the associated LED indicators. For troubleshooting measures, see page 210. 205 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Checking the LON Connection to the Vitotronic Control Unit To check the LON connection, carry out LON participants check on the Vitotronic control unit. Requirements: H The Vitocom 100 is connected to the Vitotronic control unit via LON. H All devices are switched on. H LON participants numbers are assigned to the Vitotronic control units. H The Vitotronic control unit is the fault manager. Note: The Vitocom 100 has the LON participants number “99” (fixed). Performing a participants check H Heat source installation and service instructions or H Vitotronic control unit service instructions Note: If the participants check was successful, LON service display “1” flashes green (see page 204) at the Vitocom 100 for approx. 1 min and “Check OK” appears in the Vitotronic display. Updating LON participants list In the following cases, the LON participants list in the Vitocom 100 must be updated: H New LON participants installed. H LON participants has been removed. H The LON communication module of an existing participant has been replaced. 206 5776 774 - 05 To update the LON participants list, hold down reset button “T4” (see page 203) for approx. 10 sec. Note: If the reset button is held down for approx. 30 sec., the Vitocom 100 is returned to its factory set condition. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocom 100, LAN 1 Configuring Network Using Static IP If dynamic IP addressing (DHCP, factory setting) is not being used. Version 1: Network with static IP addressing Version 2: Network still set to dynamic IP addressing The router and network are already set to static IP addressing. 1. Press maintenance button “T1” on the Vitocom 100 for at least 15 sec (max. 25 sec). The Vitocom 100 is now set to static IP address “192.168.10.90”. Only after the Vitocom 100 has been set to static IP addressing should the router and network be adjusted (by an IT contractor). 2. Connect the Vitocom 100 to a computer using the LAN cable. Note: The computer’s network card must be configured to “192.168.10.10”. 2. Determine the current IP address of the Vitocom 100 via the DSL router. 3. Enter the current IP address of the Vitocom 100 (“192.168.10.90”) into the web browser. The network configuration web page appears. 4. Select language in the upper right section of the page. 5. Enter user name and password (fixed): “User name”: vitocom “Password”: viessmann 6. Set “DHCP” to Off. Dynamic IP addressing is switched off. 7. Ask the IT contractor to set a valid configuration: ■ “IP address” ■ “Subnet mask” ■ “Gateway” ■ “DNS server 1” ■ “DNS server 2” Note: ■ The IP address must not be assigned. ■ An incorrect entry or spelling is indicated with a red border around the relevant entry field. ■ The IP addresses of the DNS servers need be specified only if such servers are used in the internal network. 5776 774 - 05 8. Store the settings using “Save”. A web page appears confirming that the process has been successful. 1. Connect the Vitocom 100 to the LAN network (DSL router) using the LAN cable. 3. Enter the current IP address of the Vitocom 100 into the web browser. The network configuration web page appears. 4. Select language in the upper right section of the page. 5. Enter user name and password (fixed): “User name”: vitocom “Password”: viessmann 6. Set “DHCP” to Off. Dynamic IP addressing is switched off. 7. Ask the IT contractor to set a valid configuration: ■ “IP address” ■ “Subnet mask” ■ “Gateway” ■ “DNS server 1” ■ “DNS server 2” Note: ■ The IP address must not be assigned. ■ An incorrect entry or spelling is indicated with a red border around the relevant entry field. ■ The IP addresses of the DNS servers need be specified only if such servers are used in the internal network. 8. Store the settings using “Save”. A web page appears confirming that the process has been successful. 9. Ask the IT contractor to set the DSL router to static IP addressing. 207 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Registering the User/Setting up the Heating System For operation of the heating system via the Vitodata 100 user interface and the Vitotrol app, a user account must be created on the Vitodata server and the heating system must be set up. For this, carry out one-off user registration. Via the Vitodata 100 user interface Via the Vitotrol app 1. Start the Vitotrol app. 2. On the start page, press “Register” and complete all fields on the registration form. 2. Press on "Create access" and complete all fields on the registration form. Note: - In the "Password" field, assign a new password (min. 6 characters: a..z, A..Z, 0..9) and confirm this in the "Enter password again" field. - "Connection data" can be found on the Vitocom 100 type plate. 3. Press “Register”. An email is sent (Subject: “Your registration for the Vitodata 100”) is sent with an activation link to the previously specified email address. 4. Open the email in your inbox and follow the activation link provided to complete the registration. The user account and the system are fully set up. 5. In the Vitotrol app, press “Log in” and log in with the following access details: User name: Password: Email address specified Password indicated The heating system can be operated via the Vitotrol app. Refer to Vitotrol app online help Note: It is also possible to register via the Vitodata 100 user interface, using the access details specified. Register user 1. Open with internet browser “http://www.vitodata100. viessmann.com”. Note: In the “Password” field, assign a new password (min. 6 characters: a..z, A..Z, 0..9) and confirm this in the “Enter password again” field. 3. Press “Next”. 4. Check and enter the confirmation code from the graphic displayed. Tick to accept the terms of use. 5. Press “Register”. An email is sent (Subject: “Your registration for the Vitodata 100”) with an activation link to the previously specified email address. 6. Open the email in your inbox and follow the activation link provided to complete the registration. The user registration is complete. The user account is fully set up. Setting up the heating system 1. Open with internet browser “http://www.vitodata100. viessmann.com” and log in to the Vitodata server. User name: Password: Email address specified Password indicated 2. Select “Create a new system”, select system type “Vitocom 100, type LAN1” and enter “Connection data”. Note: The manufacturer’s details can be found on the Vitocom 100 type plate. Refer to Vitodata 100 online help Function Test 1. Simulate a fault in the heating system, e.g. sensor fault. Refer to the heat source Service Instructions. 2. Check the following: H Operating status display "4" (see page 203) flashes red. Note: - If a fault is rectified, this is confirmed with a message. - If the fault is not rectified, then a repeat message is sent on the 3 days following. 208 5776 774 - 05 H The fault message is displayed in the Vitotrol app and sent to the recipients stored in the Vitodata 100. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Vitocom 100, LAN 1 Enabling Maintenance With this function, the transfer of messages from the heating system to the Vitodata server is suppressed, e.g. for maintenance work. 1. Prior to maintenance work on the heating system, briefly press the maintenance button “T1” (approx. 1 sec). H Operating status display “4” (see page 203) illuminates red. H The message “Maintenance button ON” is displayed in the Vitotrol app and sent to the recipients stored in the Vitodata 100. Note: If the maintenance button was not pressed before maintenance work, then a fault message may be sent, depending on the activity. 2. Briefly press the maintenance button again once the maintenance work has been carried out (approx. 1 sec). H The operating status display “4” (see page 203) changes from red to green (if no fault has developed in the heating system). H The message “Maintenance button OFF” is displayed in the Vitotrol app and sent to the recipients stored in the Vitodata 100. Note: The maintenance function is automatically reset after 8 h. Regular Function Testing The functionality of the message paths must be checked at regular intervals(see “Function testing” on page 209). Return to Factory Set Condition Press reset button “T4” (see page 203) (approx. 30 sec), until operating status display “4” and IP connection status display “3” go out. The following processes are performed: H The Vitocom 100 LON participant list is updated. 5776 774 - 05 H The Vitocom 100 is newly initialized (see page 203). 209 Vitocom 100, LAN 1 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Troubleshooting Measures Faults on the Vitocom 100 are indicated by various LED indicators (see page 203). Faults with LED indicator Type of fault and measures IP connection status”3” Flashes yellow slowly IP address could not be obtained. H Check LAN connecting cable. H At the router, check whether DHCP has been set, check other network settings. H If necessary, replace the Vitocom 100. Flashes yellow quickly IP address obtained, but no internet connection. H Check internet connection using another LAN participant, e.g. laptop. H If no internet connection is possible even with another LAN participant, have the network settings checked at the DSL router by an IT expert. Illuminates yellow Internet connection available, but the Vitodata server cannot be reached. Disconnect plug-in power supply unit and reconnect again after approx. 15 sec. Connection attempt is repeated (see page 202). Operating status display “4” Flashes green longer than 3 min Fault when initializing the Vitocom 100 H Disconnect plug-in power supply unit and reconnect again after approx. 15 sec. H If necessary, replace the Vitocom 100. 210 Fault Measures All displays on the Vitocom 100 are off. Check the Vitocom 100 power supply. The messages are displayed in the Vitotrol app, but not sent to the recipients. Check configuration of the recipients in the Vitodata 100. The Vitocom 100 reports “participant failure”. Check LON connecting cables. 5776 774 - 05 Faults without LED indicator Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Connection and Wiring Diagrams Burner Control Unit Connection Diagram WARNING Disconnect power inside the boiler junction box, before servicing boiler. 5776 774 - 05 Legend A Burner control unit interface VUC 310/base B Flame sensor aA C Vitotronic control unit D Ignition burner inlet damper E Ignition unit gF F Gas valve V1 dG G Gas valve V2 dH H Fan motor with PWM control and feedback 100 A I Boiler temperature sensor 1 3 A J Boiler temperature sensor 2 3 B CAUTION Provide disconnect means and overload protection as required. AC-EMI suppression filter device Flue gas temperature sensor 1 15 A Flue gas temperature sensor 2 15 B Inlet fan pressure switch acA (APS1) Overfire pressure switch acAA (APS2) Inlet gas pressure switch ayA GDW1 Gas pressure switch (outlet pressure at first valve seat) kJ GDW2 R Shut off damper S Burner display and programming unit F1/F2 Fuse K L M N O P Q 211 Connection and Wiring Diagrams Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Legend A Supply temperature sensors heating circuits M2/M3 B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connections 212 D Boiler power supply connection E Pumps/mixing valve connections F Internal disconnect switch (with lockout provision) 5776 774 - 05 Boiler Connections Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Connection and Wiring Diagrams 5776 774 - 05 Overview Legend A1 PCB extension for heating circuits 2 and 3 with mixing valve, boiler section 1 control only A2 PCB, low voltage A3 PCB, 120 V~ A6 Programming unit connection PCB A7 Optolink PCB / emissions test switch A8 A9 A10 A11 A12 A13 X PCB Coding card LON communication module Power supply unit PCB Programming unit ON/OFF switch Programming unit Electrical interfaces 213 Connection and Wiring Diagrams Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service PCB Extension for Heating Circuits 2 and 3 with Mixing Valve PCB, extension for heating circuits 2 and 3 with mixing valve ? M2/M3 sÖ M2/M3 fÖ gS M2/M3 K1-K6 X Supply temperature sensors Heating circuit pumps Power supply Mixing valve motors Relay Electrical interfaces Legend ! Outdoor temperature sensor ?/§ Supply temperature sensor / common system supply temperature %A DHW Tank temperature sensor %B DHW tank temperature sensor for tank loading system aG Without function aJA Without function aJB Temperature sensor, DHW tank loading system 214 avD avG avH LON S3 V1 V2 X External connections KM-BUS participants External connections Connecting cable for data exchange (accessory) Emissions test switch Fault display (red) Operating mode display (green) Electrical interfaces 5776 774 - 05 PCB, Low Voltage Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Connection and Wiring Diagrams PCB 120V~ Legend sÖ 5776 774 - 05 sA sK sL fÖ fA gÖ gS Heating circuit pump or primary pump, tank loading system Circulation pump for DHW tank heating (accessory) DHW recirculation pump (on-site) Boiler circuit pump or distributor pump (on-site) Power supply, 120 V/60 Hz Burner Output for central fault message Motor for 3-way mixing valve, primary store system aBÖ aBA aBH F K2-K10 S1 X External connections (remove jumper when connecting) Safety chain (potential free) Power supply for accessories MCB/fuse Relays On/off switch Electrical interfaces 215 Additional Information Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Requirements for Water Conditions Fill and make-up water Total quantity of water USG USG USG Total hardness Feed water pH-value Date Boiler water 5776 774 - 05 216 Counter reading Specifications Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Boiler Dimensions CA3 3.5 and 4.0 CA3 5.0 and 6.0 Dimensions 5776 774 - 05 Boiler Model Dimensions 3.5 and 4.0 5.0 and 6.0 3.5 and 4.0 5.0 and 6.0 L in. (mm) 6 (152) 6 (152) 39e (1000) M in. (mm) 11c (299) 11c (299) 84 (2131) 84 (2131) N in. (mm) 40 (1015) 44 (1118) in. (mm) 96f (2453) 133 (3376) O in. (mm) 32a (820) 32a (820) E in. (mm) 36 (936) 36 (936) P in. (mm) 14 (357) 14 (357) F in. (mm) 78 (2002) 78 (2002) G in. (mm) 74e (1887) 74e (1887) H in. (mm) 64d (1628) 64d (1628) I in. (mm) 26a (665) 26a (665) J in. (mm) 9c (248) 9c (248) K in. (mm) 79a (2013) 111d (2823) A in. (mm) 101f (2581) 138 (3503) B in. (mm) 39e (1000) C*1 in. (mm) D Boiler Model Legend SA Safety header KV Boiler supply LG Natural gas connection KR Boiler return AGA Flue gas outlet (vent pipe connection) *1 Total height does not include the concrete pad (see page 13). 217 Specifications Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Technical Data Boiler Model Input Overall Boiler Length (including insulation and jacketing) CA3 MBH (kW) MBH (kW) MBH (kW) MBH (kW) % % ”w.c. (max.) ”w.c. (min.) Voltage Phase Hz Amp. in. (mm) 3.5 3500 (1026) 300 (88) 3360 (985) 2922 (856) 96.1 96.0 14 4 120 1 60 20 101f (2581) 4.0 4000 (1172) 400 (117) 3840 (1125) 3339 (979) 96.1 96.0 14 4 120 1 60 20 101f (2581) 5.0 5000 (1465) 300 (88) 4800 (1407) 4174 (1223) 96.1 96.0 14 4 208*2 3 60 20 138 (3503) 6.0 6000 (1758) 400 (117) 5760 (1688) 5009 (1468) 96.1 96.0 14 4 208*2 3 60 20 138 (3503) Overall Boiler Width (including insulation and jacketing) in. (mm) 39e (1000) 39e (1000) 39e (1000) 39e (1000) Overall Boiler Height (including insulation and jacketing) in. (mm) 84 (2131) 84 (2131) 84 (2131) 84 (2131) in. (mm) in. (mm) in. (mm) 82f (2100) 39e (1000) 4 (100) 82f (2100) 39e (1000) 4 (100) 114d (2900) 39e (1000) 4 (100) 114d (2900) 39e (1000) 4 (100) lb. (Kg) 4982 (2260) 5093 (2310) 6592 (2990) 7187 (3260) Minimum Input NG Output Net AHRI Rating Combustion efficiency*1 Thermal efficiency*1 NG Supply Pressure Power Supply Concrete boiler base*3 Length Width Thickness Weight Complete with the burners, control, thermal insulation and jacketing *1 Tested to U.S. Standards ANSI Z21.13/CSA 4.9 *2 Requires 208Y/120VAC - 3phase- 60 Hz - 4 wire (L1, L2, L3, N, G) power supply. *3 Concrete boiler pad is required for all installations (refer to page 9 for additional information). Note: For altitude operation up to 4,999 feet, derate the input capacity by 3%/1000 ft. For operation from 5,000 to 10,000 feet, with the electronic altitude adjustment made, derate the input capacity by an additional 0.6%/1000 ft. for a total derate of 18%. A Input capacity after electronic altitude adjustment is made. 218 5776 774 - 05 A Specifications Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Technical Data (continued) Boiler Model Boiler Water Content CA3 USG (L) 3.5 151 (570) 4.0 143 (540) 5.0 227 (860) 6.0 218 (825) Heat Exchanger Surface ft.2 (m2) 170.2 (15.8) 192.5 (17.9) 244.1 (22.7) 288.8 (26.8) Maximum Operating Temperature °F (°C) °F (°C) psig (bar) 210 (99) 203 (95) 160 (11) 210 (99) 203 (95) 160 (11) 210 (99) 203 (95) 160 (11) 210 (99) 203 (95) 160 (11) in. (mm) 4 (100) 4 (100) 4 (100) 6 (150) in. in. in. in. 2 2@1a c 2b 2 2@1a c 2b 2 3@1a c 3 2 3@1a c 3 in. (mm) 12 (306.8) 12 (306.8) 16 (408.4) 16 (408.4) in. (mm) 12 (306.8) 12 (306.8) 16 (408.4) 16 (408.4) °F (°C) 117 (47) 117 (47) 122 (50) 122 (50) °F (°C) 91 (33) 91 (33) 91 (33) 91 (33) °F (°C) 162 (72) 162 (72) 167 (75) 167 (75) lbs/h (kg/h) 3109 (1410) 3549 (1610) 4442 (2015) 5324 (2415) lbs/h (kg/h) 320 (145) 425.5 (193) 320 (145) 425.5 (193) USG/h (L/h) 34 (129) 38 (144) 48 (182) 58 (220) 100 0.4 100 0.4 100 0.4 100 0.4 8750 (2564) 0.25 10000 (2931) 0.25 12500 (3663) 0.25 15000 (4396) 0.25 Maximum Adjustable High Limit Maximum Operating Pressure Boiler Connections Boiler supply and return (BS), (BR) (ANSI flanges) Safety supply Boiler drain Condensate drain (barbed fitting) Gas connection Vent Pipe Internal diameter Combustion Air Internal diameter (for direct vent sealed combustion) Flue Gas Values Temperature (at a return temperature of 86°F (30°C) at rated input at partial load Temperature (at a return temperature of 140°F (60°C) at rated input Mass flow rate (of flue gas) at rated input at partial load 5776 774 - 05 Max. Condensate Flow Rate for NG Pressure at boiler flue outlet at rated input Standby Loss At boiler water temperature 158°F (70°C) [room temperature 68°F (20°C)] pa (max.) “w.c. (max.) BTU/h (W) % 219 Inspection and Maintenance Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Maintenance Record Setting and Test Values Commissioning Maintenance/Service mbar (”w.c.) Section 1 Section 2 Section 3 Section 1 Section 2 Section 3 Static Pressure Supply Pressure (running pressure) mbar (”w.c.) for natural gas NG Carbon Dioxide Content CO2 ■ at the upper rated heating output ■ at the lower rated heating output actual % by vol. set % by vol. actual % by vol. set % by vol. actual % by vol. set % by vol. actual % by vol. set % by vol. Oxygen Content O2 ■ at the upper rated heating output ■ at the lower rated heating output Carbon Monoxide Content CO Flue Gas Temperature (gross) actual ppm set ppm actual °F (°C) set °F (°C) Ionization Current ■ at the upper rated heating output μA ■ at the lower rated heating output μA Draught actual hPa (”w.c.) set hPa (”w.c.) Maintenance Schedule The following is an overview of scheduled service steps. Regular service work ensures reliable, energy-efficient, and environmentally friendly operation. IMPORTANT Keep boiler and boiler room clear and free from combustible materials, gasoline and other flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air. All inspection, maintenance, and service must be performed by a qualified heating technician. IMPORTANT 220 5776 774 - 05 The boiler must be cleaned at least once a year by a qualified heating technician or service agency. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Maintenance Schedule Frequency Performed by Monthly Owner / Operator Annually Owner / Operator Heating Technician 5776 774 - 05 Periodically Heating Technician Inspection and Maintenance (continued) Service Check the system pressure frequently. Ensure proper operation of the boiler control. Refer to operating instructions of the control. Inspect all seals; retighten or replace as necessary. Ensure an adequate supply of combustion air and ventilation air into and out of the mechanical room is being maintained at all times. Ensure that nothing is obstructing the flow of combustion ventilation air, and no chemicals, garbage, gasoline, combustible materials, flammable vapors, or liquids are stored, not even temporarily, in the vicinity of the boiler. Check for water on the floor from the discharge pipe of pressure relief valve or any other pipe, pipe joint, valve, or air vent. Test pressure relief valve and check for proper operation. See instructions attached to pressure relief valve. Check all operational high limits for proper operation. Check for proper operation of the condensate neutralization system (if used). Check the condition and fill status of the neutralization media. Check the pH value of the flue gas condensate (min. 6.5). Check for moisture water on external vent pipe joints and appearance of ice on the vent pipe or chimney outlet in the winter time. Ensure service work/test is conducted at least annually by qualified personnel, and that any deficiencies are corrected immediately. Test functionality of safety high limits. Test and establish proper chemical makeup of system water. Check flue pipe condition, chimney connection and chimney itself. Check pressure relief valve and system pressure, and verify proper operation. Check heating pipe joints, valves, air vents, etc. System leaks must be corrected immediately to avoid further defects. The cause of defect must also be determined in order to avoid further problems. Check for proper combustion air supply and ventilation to boiler / mechanical room. Test high limits by dialing lower settings, then switching burners on/off to verify function. Test low water cut-off, check and verify proper function according to manufacturer’s instructions. Check requirements for maintenance or lubrication of the circulation pumps according to manufacturer’s instructions. Check for gas-tight connection of gas piping, unions, gas valve and manifold. Check proper ignition of the burners. Combustion test must be performed by a qualified heating technician. Ensure functionality of low water cutoffs, including flushing of float types (if used) during operation. Refer to the manufacturer’s instructions. Inspect low- and/or high pressure gas switch (if used). Inspect main burner flame and follow the instruction manual for detailed service and maintenance guidelines. All boilers and the boiler room must be kept free of high dust levels, high humidity, aggressive vapors and/or chemicals containing chlorine. Ensure proper boiler room ventilation. Valves, fittings and pipes not pressure tight must be repaired. Combustion chamber door, clean-out opening covers, and flanges may need to be retightened and resealed. Do not over tighten. 221 222 5776 774 - 05 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service 5776 774 - 05 Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service 223 Scan for digital copy of this document 5776 774 - 05 Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper. Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service