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
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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)
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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).
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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
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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
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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)
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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.
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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.
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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
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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
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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.
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2. Close central gas shut-off valve.
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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.
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2. Remove 6 nuts.
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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.
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2. Lift out mounting plate with burner tube.
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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.
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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.
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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.
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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)
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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
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3B sensor (NTC 20k) terminals 3 & 4
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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.
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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.
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5. Reinstall spring clip.
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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
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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
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7 in. (mm)
7
(200)
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Service
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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.
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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.
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6. For further steps, see chapter “Further assembly”
on page 101.
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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.
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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
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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.
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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
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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.
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3. Replace any damaged parts.
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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”.
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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
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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.
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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.
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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.
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4. Engage motor lever.
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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.
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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 - 3phase- 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
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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
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Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service