5790 733 - 14 - viessmann€¦ · 5790 733 - 14 vitocrossal 300 ca3 series 2.5 to 6.0...

Installation and Service Instructions

VITOCROSSAL 300

5790 733 - 14 05/2019

for use by heating contractor

Vitocrossal 300 CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0Gas condensing boiler with cylinder burners

Read and save these instructionsfor future reference.

Please file in Service Binder

Product may not be exactly as shown

IMPORTANT

H

Heating input: 2500 to 6000 MBH (733 to 1758 kW)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Safety, Installation and Warranty RequirementsSafety

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).

WARNINGInstallers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the boiler containedin this manual.

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.

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 this manual.

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.

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 this manual.

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 this manual.

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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Safety, Installation and Warranty Requirements (continued)

Safety

WARNINGInhaling of fiberglass wool and/or ceramic fiber materials is a possible cancer hazard. These materials can also cause respiratory, skin and eye irritation.

Fiberglass wool and ceramic fiber materials

WARNINGAppliance 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.

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.

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.

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.

CodesThe 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 roomEnsure the mechanical room complies with the requirements of this 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.

The maximum room temperature of the mechanical room where the boiler is located must not exceed 104°F (40°C).

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 cold water (as warm or hot water may worsen the irritation). 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.

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Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service Table of Contents

Safety

General Information

Installation

System Layout

Venting

Page

Safety, Installation and Warranty Requirements ............ 2

Important Regulatory and Installation Requirements ........8About these Installation Instructions ...........................10Product Information ..................................................10Mechanical Room .....................................................11For Retrofit Applications ............................................11

Recommended Minimum Service Clearance .................12Unpacking and Placement of Boiler .............................13Reducing Boiler Height ........................................... 13Preparing the Boiler ..................................................14Water Side Connection ........................................... 14Boiler Connections ....................................................15Electrical Connections............................................ 18Activating the Boiler Section Valves ......................... 35Extension EA1 Accessory (optional) ......................... 36Making the LON Connection ......................................37Vitocom 100, LAN 1 ................................................38Vitocom 100, LAN 1 Requirements ............................39Operation with Vitotrol App .................................... 40Operation with Vitotrol 100 User Interface ..................41Checking Network Settings ..................................... 41Vitocom 100, LAN 1 Internal Overview .......................42Connecting to the Network (LAN) ...............................42Vitocom 100, LAN 1 Display and Control Elements ..... 43Switching on the Vitocom 100, LAN 1 ........................43Configuring Network Using Static IP ...........................44Registering the Vitocom 100, LAN 1 ........................ 45Function Test ..........................................................45Enabling Maintenance ............................................ 46Return Vitocom 100, LAN 1 to Factory Set Condition .. 46Troubleshooting Measures for Vitocom 100, LAN 1 ......47Connecting Flue Gas Pipe ..........................................48Connecting Neutralization System ..............................49Condensate Connection ............................................50Gas Connections ......................................................51Initial System Fill ................................................... 54

General ...................................................................55System Layout 1 .................................................. 56System Layout 2 .................................................. 57Boiler Piping in Heating/Cooling Application .................58

General Venting Information ......................................59Connecting Combustion Air Intake for Direct Vent ........62Additional Requirements for Stainless Steel Vent Pipe Material ....................................................62Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material ....................................................63Vent Requirements ................................................ 64Direct Venting (Two Pipe System) ..............................65Side Wall Venting ................................................. 66Component Installation Guide .................................. 66Elbow - Equivalent Length ...................................... 66Vent Termination Location Requirements - Vertical .......67Installation of Support System - PP(s) .........................67

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Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service

Venting Options - Stainless Steel/PP(s)

General Service Information

Service

Table of Contents

Two Pipe System - Vertical Exhaust/ Vertical Air Intake ....................................................68Two Pipe System - Horizontal Exhaust/ Horizontal Air Intake .................................................70Two Pipe System - Vertical/Horizontal Installations .......71Individual Burner Intake Ducting .............................. 72Single Pipe System - Vertical Exhaust/ Room Air Dependant .................................................73Single Pipe System - Horizontal Exhaust/ Room Air Dependant .................................................74Multiple Boiler Installations ..................................... 75

Service Equipment ....................................................76Important Regulatory and Installation Requirements ......77Safety Instructions ................................................ 78

Filling the Heating System with Water and Ventilating .. 80Filling Condensate Trap with Water ............................80Checking the Type of Gas .........................................80Operating the System ........................................... 81Adjusting the Heating Curve ......................................84Integrating the Control Unit into the LON.....................86Preparing for Service Work on the Boiler and Burner .....88Reducing Operational Output (if required) ....................90Checking Static and Connection Pressure ....................91Checking the Rotary Damper Setting ..........................92Checking the Burner Damper Setting...........................92Measuring CO2 Content ............................................93Displaying Ionization Current .................................... 95Turning the System Off .............................................95Dismantling the Burner........................................ 96Burner Parts ...........................................................98Display and Programming Unit of Burner Control Unit ...99Coding Card on Burner Control Unit ...........................99Burner Control Unit ................................................100Fuel Conversion NG to LPG .....................................101Burner Interface Panel .............................................1033A and 3B Boiler Temperature Sensor Description ......104Boiler Water Temperature Sensor .............................105Boiler Secondary Temperature Sensor .......................106Manual Reset Limits ...............................................107Gas Valve .............................................................108Air Pressure Switches ...........................................108Ignition Unit ..........................................................111Ignition Cables .......................................................112Rotary Damper and Servomotor ...............................112Replacing the Solenoid Valve ...................................112Fan .......................................................................113Checking and Cleaning the Burner Tube ....................113Checking the Ignition Electrodes and Ionization Electrode .114Cleaning the Burners .............................................114Cleaning the Combustion Chamber and Heating Surfaces ...................................................115Checking Heating Water Connections for Leakage ......116Cleaning the Condensate Drainage System ................116

Page

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Service (continued)

Function Description

Coding Levels

Coding Level 1

Coding Level 2

Service Scans

Troubleshooting

Table of Contents

Further Assembly and Commissioning .......................117Checking for Flue Gas Leakage .............................. 117Automatic Leakage Test for Valves of the Combined Gas Valve .............................................................117Checking On-site Gas Connections for Leakage ..........118Taking Final Measurement Reading ..........................118Checking the Water Conditions ...............................118Checking Expansion Tank and System Pressure ........ 121Mixing Valve Movement and Leak Check ...................121Checking Air Intake in the Installation Room (visual check) ........................................................122Replacing the Supply Air (for room air dependant operation) ........................................................................ 122Instructing the Operator of the System .....................122Operating and Service Documents ............................122

Boiler Water Temperature Control ...........................123Cascade Control Unit ..............................................123Heating Circuit Control ............................................128DHW Tank Temperature Control ...............................132

Calling up Coding Levels ..................................... 135Resetting Coding to their Factory Set Condition .........135

“General” Group .....................................................136“Combustion Controller” Group ................................138“Boiler” Group .......................................................138“Cascade” Group ..................................................139“DHW” Group ........................................................141“Solar” Group .................................................. 142“Heating Circuit...” Group.......................................143

“General” Group .....................................................147“Combustion Controller” Group ................................155“Boiler” Group .......................................................156“Cascade” Group ..................................................156“DHW” Group ........................................................159“Solar” Group .................................................. 161“Heating Circuit...” Group.......................................165

Calling up the Service Menu ...................................171Leaving the Service Menu .......................................172Change Passwords .................................................172Resetting all Passwords to Factory Settings .............172Scanning Operating Data ........................................172Resetting Operating Data .......................................173Brief Scan .............................................................173Carrying Out an Actuator Test ................................174Checking Sensors ...................................................175Maintenance Display ...............................................175

Fault Display ..........................................................176Boiler System Fault Codes ........................................177Burner Fault Codes ................................................183Sensors ...............................................................186

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Burner Control Unit ................................................187Resetting Operating Parameters to Factory Settings ....191Manual Mode and Service Display ............................191Burner Control Unit Flow Diagram ............................192Faults ...................................................................194Fault Codes ....................................................... 195Faults Without Fault Display ....................................198

Burner Control unit Connection Diagram ....................199Boiler Connections ..................................................201Overview ..............................................................203PCB Extension for Heating Circuits 2 and 3 with Mixing Valve .........................................................204PCB Low Voltage ................................................ 204PCB 120V~ ..........................................................205

Parts Lists ...........................................................206

Technical Data .......................................................245Boiler Dimensions ............................................... 247Requirements for Water Conditions ...........................248

Maintenance Records .......................................... 249Maintenance Schedule ............................................249

Table of Contents

Page

Burner Control Unit

Connection and Wiring Diagrams

Parts

Specifications

Inspection and Maintenance

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Information 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

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.

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WARNINGFailure 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.

CAUTIONUnder certain climatic conditions some building materialsmay 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.

For Polypropylene venting systems onlyMinimum 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.

Working on the equipmentThe 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 have been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.

Technical literatureLiterature 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.

ASME CSD-1 StandardThe 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.

IRI (Industrial Risk Insurers)IRI (Industrial Risk Insurers) requirements for boilers havebeen replaced by GE Global Asset Protection (GAP) Services requirements, please refer to section describing GE GAP requirements.

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.

FM (Factory Mutual) GlobalFM 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 (field supplied).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.

Important Regulatory and Installation Requirements (continued)

General Information

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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 burnersmust always be installed according to the instructions provided by the burner manufacturer.

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.

WARNINGExposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.

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.

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.

IMPORTANT

Warnings draw your attention to the presence of potential hazards or important product information.

Cautions draw your attention to the presence of potential hazards or important product information.

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.

WARNINGIndicates an imminently hazardous situation which,if not avoided, could result in death, serious injury or substantial product/property damage.

CAUTIONIndicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

General Information

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Vitocrossal 300 CA3 Series 2.5 to 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.

For Retrofit Applications

Before boiler is connected to piping/heating system, (which has been previously in service) the piping must be flushed with city pressure water (50-60 psi) to remove sludge and other contaminates.

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. Installation of magnetic filtration is recommended.

Do not operate when air is polluted with solvents, chlorides, fluorides, cleaning agents or particulates of any kind. Prevent very dusty conditions (if necessary install a

field supplied combustion air intake filter). See page 65 for additional information.

Prevent high levels of humidity. Prevent freezing and ensure good ventilation.

Otherwise, the system may suffer faults and damage which is not covered under warranty.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Recommended Minimum Service ClearancesPreinstallation

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.

LegendA Boiler

*1 Clearance for vent pipe installation.B Boiler combustion air intake vent

To enable convenient installation and maintenance, observe the stated clearance dimensions. Maintain the minimum clearances where space is tight.

CA3 Model

2.5 3.0 3.5 4.0 5.0 6.0

a in. (mm)

31b (800)

31b (800)

31b (800)

31b (800)

31b (800)

31b (800)

b*1 in. (mm)

30 (760)

30 (760)

30 (760)

30 (760)

30 (760)

30 (760)

c in. (mm)

39e (1000)

39e (1000)

39e (1000)

39e (1000)

39e (1000)

39e (1000)

Top clearance

31b (800)

31b (800)

31b (800)

31b (800)

31b (800)

31b (800)

Minimum clearances to combustibles

CA3 Model

2.5 3.0 3.5 4.0 5.0 6.0

Top 0

Sides 0

Flue per vent manufacturer’s specifications

Front 0

Floor combustible

CA3 2.5, 3.0, 3.5 and 4.0

CA3 5.0 and 6.0

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* CA3 boilers 2.5-3.0 3.5-6.0

Total height in. (mm)

78c (1999)

84 (2136)

Height excluding upper panels, upper in. frame elements, burners and piping (mm)

77 (1977)

77c (1975)

Positioning boilerThe 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.

Preinstallation

Unpacking and Placement of Boiler

Unpacking boiler1. 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

3. Raise boiler from the packaging platform with a lift truck or forklift.

It is essential to use appropriate lifting devices certified for lifting to a minimum of the boiler weight.

Lifting the boiler1. 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

WARNINGIf flue gas connection is damaged leakage may occur. Do not lift boiler at the flue gas connection.

When lifting the boiler from the side ensure the forks of the lift truck or forklift are centered. Refer to the mark located on the side of the boiler.

Reducing Boiler Height

Reducing the overall height of the boiler during placementThe overall boiler height can be reduced for placement. Panels, frame elements with piping and burners can be dismantled for this purpose.

4. Remove burners. See page 96. 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.

1. Dismantle panels. Top panels Upper side panels Upper rear panel

2. Dismantle boiler supply header.

3. Dismantle upper frame profile.

Dismantle the upper panels and upper frame elements with piping and burners

* Height does not include the concrete pad or seismic brackets.

CA3 Model

2.5 3.0 3.5 4.0 5.0 6.0

a in. (mm)

74c (1900)

74c (1900)

82f(2100)

82f(2100)

114d(2900)

114d(2900)

b in. (mm)

33 (860)

33 (860)

39e(1000)

39e(1000)

39e(1000)

39e(1000)

lb. (kg)

4388 (1990)

4388 (1990)

4982(2260)

5093(2310)

6592 (2990)

7187 (3260)

Boiler weight

With seismic feet (available for models 2.5 thru 6.0)

Boiler model 2.5 3.0 3.5 4.0 5.0 6.0

a in. (mm)

85a(2165)

85a(2165)

94(2388)

94(2388)

125(3175)

125(3175)

b in. (mm)

48a(1225)

48a(1225)

53(1346)

53(1346)

53(1346)

53(1346)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Installation

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 to the diagram on page 55.

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.

IMPORTANT

The Vitocrossal 300, CA3 boiler is only suited for hot water heating. Do not install a 4-way mixing valve, bypass valve or similar.

Boiler Connections

Preparing the Boiler

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.

Note: When using seismic brackets B (optional accessory) do not install levelling bolts.

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.

Note: It is recommended that the levelling bolts included with the boiler are used when installing the boiler

on uneven surfaces.

Refer to the Seismic bracket Installation Instructions when using the optional seismic mounts.

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Boiler Connections (continued)

*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.

Installation

Legend1 Boiler return: (ANSI 4 in. for models 2.5, 3.0, 3.5, 4.0 and 5.0 and ANSI 6 in. for model 6.0) *12 Boiler supply: (ANSI 4 in. for models 2.5, 3.0, 3.5, 4.0 and 5.0 and ANSI 6 in. for model 6.0) *13 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 baseC Plug b in.D Reducer 2 in. to 1 in. for models 2.5 and 3.0, 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 1 in. for models 2.5 and 3.0 1a in. for models 3.5 and 4.0 1b in. for models 5.0 and 6.0F Pressure relief valve, 75 psi *2G Low water cutoffH Temperature/pressure gauge

4 Drains: I Nipple 1b in. x 10 in.J Reducer 1b in. x c in.K Sediment faucet c in.

5 Gas line fittings:L Gas gas shut-off valve, 2b in. for models 2.5, 3.0, 3.5 and 4.0, 3 in. for models 5.0 and 6.0

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Installation Boiler Connections (continued)

LegendA Boiler supplyB Temperature/pressure gaugeC Pressure relief valveD Boiler returnE Drain valveF Precharged expansion tankG Automatic fillH Condensing water drainI Flue gas test port

All Vitocrossal 300 boilers are hydrostatically factory tested to ASME requirements.

Safety Header

1. Locate safety header on the main supply header.

Max. allowable working pressure (MAWP) .... 160 psi (11 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.

CAUTIONDo not connect heating system to safety header.

WARNINGExposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.

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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.

Boiler Connections (continued)

Installation

1. Locate and remove drain plug for each boiler section.

2. Install drain valve assembly for each boiler section as shown.

LegendA 1b in. x 10 in. nippleB 1b in. to c in. reducerC c in. sediment faucet

Installing the isolation valve handleRemove 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.

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The cable trays are on the left side of the boiler.

Electrical ConnectionsInstallation

Cable routing on boiler

IMPORTANTRoute power supply cables and low voltage cables separately using the cable trays provided.

LegendA Upper cable tray for power supply cables (e.g. boiler power supply)B Lower cable tray for low voltage cables (e.g. sensor cables)

1. Remove the screws holding the top panels and lift and remove the top panels.

2. Lift and remove upper front panel.

3. Lift and remove left side panels.

4. Using supplied ‘panel key’, unlock the front panel and swing door open.

5. Remove upper and lower front panels for the Vitotronic 300 GW6C control.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Electrical Connections (continued)

Installation

LegendA Supply temperature sensors heating circuits M2/M3B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connectionsD Boiler power supply connectionE Pumps/mixing valve connectionsF Disconnect switch with lockout provisionG Vitocom 100 LAN1

Connection overview for CA3 2.5 and 3.0

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Electrical Connections (continued)

Installation

Connection overview for CA3 3.5, 4.0, 5.0 and 6.0

LegendA Supply temperature sensors heating circuits M2/M3B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connectionsD Boiler power supply connectionE Pumps/mixing valve connectionsF Internal disconnect switch (with lockout provision)G Vitocom 100 LAN1*1 Boiler section 3 control unit (5.0 and 6.0 only)

*1

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Installation

Heating circuit - extension connection

Extra-low voltage printed circuit board connections

! 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

Low voltage connections at the system and boiler section 1 controller

Legend

? M2/M3 supply temperature sensor

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 connection 2 wire cable, 18 AWG for a maximum length of 115 ft. (35 m).

Common supply temperature sensor

H For single boilers systems, mount the common supply temperature sensor on the supply piping near the boiler.

H For multiboiler systems, mount the common supply sensor on the supply piping common to all boilers.

Refer to the system layouts, see page 55.

X11

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Installation

Accessory connectionsThe accessory terminals include a L, N terminal connection orientated at the top of the rail which is pre-wired to the cable harness set. The L, N, G terminals orientated at thebottom of the DIN rail for accessory connection is used tofor 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.

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.

Legend A DIN terminal accessory connectionsB Push-in buttonC DIN rail (typical)D Terminal insertion point

Top

Bottom

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Installation

1. Flip down the front portion of the DIN rail mounted fuse block.

2. Flip down the front side cover of the DIN rail mounted fuse block.

3. Replace fuse.

4. Return the DIN rail mounted fuse block back to the original position.

Internal control fuse F3

When fuse F3 requires replacement, (refer to the separate wiring diagram) the fuse can be accessed as shown.

Legend B Push-in buttonC DIN rail (typical)D Terminal insertion point

Main power supply connectionsThe 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 - LineBlue - NeutralGreen / Yellow - Ground

Refer to page 33 for power supply connection details.

Top

Bottom

Refer to wiring schematic for fuse F3 location.

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Installation

Legend

sÖA1 Heating circuit pump A1

sÖM2 Heating circuit pump M2


sA Circulation pump for tank heating

sK DHW circulation pump

sL Boiler circuit pump

gÖ Central fault message

gS 3-way mixing valve

gSM2/M3 Mixing valve motor 120 V~

External connections for boiler models 2.5 and 3.0

A On-site relayB On-site safety equipmentC On-site indoor air damperD Feedback contact

Note: To connect feedback contact D, remove jumper 25 L/26 L (factory set condition).

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Installation

Legend

sÖA1 Heating circuit pump A1



sA Circulation pump for tank heating

sK DHW circulation pump

sL Boiler circuit pump

gÖ Central fault message

gS 3-way mixing valve

gSM2/M3 Mixing valve motor 120 V~

External connections for boiler models 3.5 to 6.0

A On-site relayB On-site safety equipmentC On-site indoor air damper

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Installation

Connecting Pumps

Pumps 120V

Note: Maximum output 6FLA shared between all 120V outputs.

Available pump connections

sÖA1 Heating circuit 1 pumpsÖM2 Heating circuit 2 pumpsÖM3 Heating circuit 3 pumpsA DHW pumpsK DHW recirculation pumpsL Boiler pump/system pump

Available connections

Connections on extension for heating circuit with mixing valve HC2/M2, HC3/M3Plug Terminal ComponentsÖ M2 5 L, N, G Heating circuit pump

sÖ M3 6 L, N, G Heating circuit pump

Connections on the PCB 120V~sÖA1 9 L, N, G Heating circuit pump

for heating circuit A1orPrimary pump, tank loading system

sA 8 L, N, G DHW pump

sK 7 L, N, G DHW recirculation pump

sL 10 L, N, G boiler pump, system pump

Rated voltage 120V~

Rated current Max. 2A~

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Installation

Connecting Pumps (continued)

120V pumps with an amperage draw of >2FLAContactor specification 120VAC 1A

LegendA DIN rail (located in the junction box)B Contactor/relay (field supplied)C PumpD Power supply w/disconnect and protection

120V pumps with an amperage draw of <2FLA

LegendA DIN rail (located in the junction box)B Pump

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Installation

240V pumpsContactor specification 120VAC 1A


208/460/575V 3 phase pumps Contactor specification 120VAC 1A


Connecting Pumps (continued)

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Installation

Connecting a Central Fault Message Facility

Plug gÖ (terminal 11 - L, N, G)

Rated voltage 120V~

Rated current Max. 2A~

Connecting Mixing Valve Actuators1. Disconnect power to control.

2. Connect valve actuator wires to the DIN terminals as shown (based on desired functionality).

Legend A DIN Rail (in junction box) B 120V Valve ActuatorC Valve

Available connectionsgSM2 For heating circuit 2gSM3 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.

Note: Maximum output 6 FLA shared between all 120V outputs.

Plug DIN terminals

52M2 1 (L, N)

2 (L)

52M3 3 (L, N)

4 (L)

Rated voltage 120V~

Rated current Max. 0.1A~/ output

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Installation

Available connectionsgS M2 For heating circuit 2gS M3 For heating circuit 3

24V Valve AdaptorRated voltage: 24VACRated current: max. 0.15 FLA

Legend A 24V Mixing Valve AdaptorB DIN Rail (in junction box) C 24V Valve ActuatorD ValveE 120V power to the mixing valve adaptor

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 DIN terminals

gSM2 1 (L, N)

2 (L)

gSM3 3 (L, N)

4 (L)

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.

Connecting Mixing Valve Actuators (continued)

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Installation

Connection of Low Water Cut-off Device

CAUTIONThe diagram shown is only a simplified conceptualdrawing of a typical low water cut off (LWCO) device. Refer to the manual specific to the device for interconnection details.

Legend A Low water cut-off (typical)

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.

*Factory Installed high limit temperature switches (refer to page 107 for additional information).

A

* *

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Installation

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).

LegendA Minimum pressure limiterB Maximum pressure limiterC Further safety equipment

Note: Periphery equipment attached to the aBÖ plug must be operated on a normally closed circuit.

*Factory Installed high limit temperature switches (refer to page 107 for additional information).

* *

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Installation

DIN rail X0 Power supply connectionCA3 2.5, 3.0, 3.5 and 4.0

120 VAC/60 Hz/1 phase (20 Amps - full load amperage)

240 VAC/60 Hz/1 phase (20 Amps - full load amperage)

208 Y/120VAC-60Hz - 3 phase (20 Amps - full load amperage)

(4 wire L1, L2, L3, N, G)

DIN rail X0 Power supply connectionCA3 5.0 and 6.0

Legend1 Factory installed terminal bridge2 Terminal bridge must be removed on site for 240VAC connection.

WARNINGIncorrectly executed electrical installations can lead to injuries from electrical current and result in appliance damage.

WARNINGThe control must be grounded. Ensure that ‘L’, ‘N’ and ‘G’ are not interchanged.

DIN rail X0 Power supply connection (optional)CA3 2.5, 3.0, 3.5 and 4.0

IMPORTANT

Electrical installations must comply with the latest edition of: In the U.S.A., the National Electrical Code (NEC),

ANSI/NFPA 70 and any other state, local codes and/or regulations.

In Canada, the Canadian Electrical Code (CEC), CSA C22.1 Part 1 and any other province, territory,

local codes and/or regulations.

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External block via output contact Connection options:

Extension EA1 (accessories, see page 36). 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.

There is no frost protection for the heating system during the block.

Connection

EA1 extension

LegendA Potential-free dry contact B EA1 Extension

Coding

EA1 extension Set “5D“ (DE1), “5E“ (DE2) or “5F“ (DE3) in the

“General” group to 3 or 4.


CAUTIONThe external connection must be potential-free.

IMPORTANT

Installation

Connection at input 0 – 10V to EA1extension (accessory, see page 36).

Note: Ensure DC separation between the ground conductor and the negative pole of the on-site voltage source.

0 –1V No default set supply temperature1V Set value 50°F (10°C)10V Set value 212°F (100°C)Observe coding “1E” in the “General” group.

Optional setting range0 –1V No default set supply temperature1V Set value 86°F (30°C)10V Set value 248°F (120°C)Observe coding “1E” in the “General” group.

External Demand via 0 –10V Input

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Electrical Connections (continued)

Installation

External Operating Program - Changeover Connection options:

EA1 extension (accessories, see page 36)

Connection

LegendA Potential-free contactB EA1 extension

EA1 Extension The changeover for heating circuits 1 to 3 can be implemented separately.

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.

CAUTIONThe external connection must be potential-free.

Preselected operating program (Contact open)

Coding Changed over operating program (Contact closed)

9or

Central heating off/DHW heating off “d5:0“ in the “Heating circuit...“ group (factory set condition)

Constant operation with reduced room temperature/DHW heating off.

wor

Central heating off/DHW heating on “d5:1“ in the “Heating circuit...” group

Constant operation with standard room temperature, coding as per DHW heating “64“ in the “DHW“ group.

rw Central heating on/DHW heating on

Coding EA1 extension

Activating the Boiler Section Valves

When the burners are shut off and all boiler section valves are closed, ventilation of the system is nolonger guaranteed.

To keep the boiler section valves of the lead boiler open, perform the following tasks:

Insert an EA1 extension with fixed jumper at input DE1

Request by building management system (BMS) at input 0–10 V [e.g. 2 V 68°F (20°C)]

Required master coding: 5D: 2 and 9B: 1

Request by building management system (floating contact) at plug aVH (terminal 2–3).

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Extension EA1 Accessory (optional)

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 0–10VThe 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 line voltage 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°F to 212°F (0°C 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°F to 248°F (30°C to 120°C) 1V ≙ 86°F (30°C) set value change 10V ≙ 248°F (120°C) set value change

Output aBJConnection 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.

Digital data inputs DE1 to DE3Functions:

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 assignmentSelect 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 circuitsThe 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



The effect of the heating program changeover is selected via coding address “d5” in the “Heating circuit...” group.

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.

Refer to the EA1 module Installation Instructions

Installation

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Making the LON Connection

Installation

Connection with Viessmann LON cable

Installation distance ≤ 23 ft. (7 m) long.

LegendA 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

Connection with Viessmann LON cable and coupling Installation clearance 23 to 69 ft. (7 to 21 m).

LegendA 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 resistorD LON coupling LON External LON participants

Connection with on-site cable and LON plug Installation distance ≤ 3000 ft. (900 m) (with LON plug).

LegendA Vitocrossal 300 CA3 control unit (Vitotronic 300 GW6C)B On-site cable C Terminating resistorD LON plugF 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).

LegendA 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

Establishing a LON-Connection The Viessmann LON is designed for the BUS-topology “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.

For details on Vitotronic 300 GW6C LON connections refer to page 86.

Types of cable (on-site): 2-core cable, CAT5, screened JY(St)Y 2 x 2 x 0.8 mm (Telephone cable)

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.

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LiabilityViessmann 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.

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 these installation and service instructions.

The respective range of functions willonly be available if the following conditionsare 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 45).

H In order to send messages via the Vitodata 100, the recipients must be set up correctly on the Vitodata server.

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.

Vitocom 100, LAN 1Installation

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Vitocom 100, LAN 1 Requirements

User account on the Vitodata serverOperating a Vitocom 100 and using the Vitotrol app require a valid user account on the Vitodata server. Registration is possible either using the Vitodata 100user interface or the Vitotrol app (see page 45).

Control device for the Vitotrol appRecommended 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 interfaceComputer 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”).

H Fax for receiving messages (only with internet service “Vitodata 100 fault management”).

IP networkDSL 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.

Installation

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Operation with the Vitotrol App

FunctionsVitotrol app control functions

H Setting set temperatures.

H Setting operating programs.

H Scanning operating conditions and temperaturesNote: 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.

Forwarding messagesPending 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

H Message text

LegendA Vitocrossal 300 CA3 with integrated Vitocom 100B IP network (on site)C DSL router (on site)D Secure internet connection to the Vitodata serverE Vitodata serverF Mobile end device (see page 39) with the Vitotrol app:

H Remote control of the heating system. H Message retrieval.

For remote control of Viessmann heating systems with Vitotronic control units via IP networks.

Installation

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Forwarding messagesPending 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 onthe 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

Operation with Vitodata 100 User Interface

For remote monitoring and control of Viessmann heating systems with Vitotronic control units via IP networks.

FunctionsVitodata 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

LegendA Vitocrossal 300 CA3 with integrated Vitocom 100B IP network (on site)C DSL router (on site)D Secure internet connection to the Vitodata serverE Vitodata server, registration and log-in via www. vitodata100.viessmann.comF Computer:

H Remote control of the heating system via the Vitodata 100 user interface

H Receipt of messages via email

G Fax for receiving messages (only with internet service “Vitodata 100 fault management”)H Mobile phone for receiving messages via SMS (only with internet service “Vitodata 100 fault management”)

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.

H Port 80 and port 443 must be approved for outgoing connections.

Installation

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Vitocom 100, LAN 1 Internal Overview

Legend! Plug-in power supply unit connection, 5 V–, internal +, external –, minimum 0.6A (preinstalled)§ Not Used$ RJ 45 connector for LAN connection cable to DSL router) 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 (preinstalled)

A Rating plate"T1" Maintenance button"T2" No function"T3" LON key, only when integrating the Vitocom 100 into a BMS (send service PIN)."T4" Reset button"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)

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)

Without cover

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Vitocom 100, LAN 1 Display and Control Elements

With cover“T1” Maintenance button (see page 42) “3” IP connection status (green and yellow LED)“4” Operating status display (green and red LED)

LON service indicator “1”Flashes green LON participant check successful (see page 87).

IP State of connection “3”

Flashes yellow/illuminates yellow Establishing a connection (see page 86), or connection fault (see page 47), 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”Illuminates red Enabling maintenance (see page 46).Flashes red Heating system fault.Flashes green longer than 3 min Fault when initializing the Vitocom 100 (see page 47).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.

Explanation of displays

Switching on the Vitocom 100, LAN 1

InitializationWhen 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” 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” 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.

Initialization successfulThe Vitocom 100 is ready for operation. The following LED indicators illuminate green: operating status display “4” and IP connection status “3”.

Initialization not successfulIf a fault occurs during initialization, this is indicated by the associated LED indicators. For troubleshooting measures, see page 47.

Installation

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If dynamic IP addressing (DHCP, factory setting) is notbeing used.

Version 1: Network with static IP addressing

The router and network are already set to static IPaddressing.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”.

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”.

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.

8. Store the settings using “Save”. A web page appears confirming that the process has been successful.

Configuring Network Using Static IP

Version 2: Network still set to dynamic IP addressing

Only after the Vitocom 100 has been set to static IPaddressing should the router and network be adjusted(by an IT contractor).

1. Connect the Vitocom 100 to the LAN network (DSL router) using the LAN cable.

2. Determine the current IP address of the Vitocom 100 via the DSL router.

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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Registering the Vitocom 100, LAN 1

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 heatingsystem must be set up. For this, carry out one-off user registration.

Via the Vitotrol app1. Start the Vitotrol app.

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: Email address specifiedPassword: 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.

Via the Vitodata 100 user interface

Register user

1. Open with internet browser “http://www.vitodata100. viessmann.com”.

2. On the start page, press “Register” 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.

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: Email address specified Password: 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

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 43) flashes red.

H The fault message is displayed in the Vitotrol app and sent to the recipients stored in the Vitodata 100.

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.

Function Test

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Enabling Maintenance

Return Vitocom 100, LAN 1 to Factory Set Condition

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 43) 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 43) 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 hours.

Press reset button “T4” (see page 43) (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.

H The Vitocom 100 is newly initialized (see page 43).

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Troubleshooting Measures for Vitocom 100, LAN 1

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 42).

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.

Faults without LED indicator

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.

Faults on the Vitocom 100 are indicated by various LED indicators (see page 43).

Faults with LED indicator

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CA3 Model 2.5 3.0 3.5 4.5 5.0 6.0

in.(mm)

10(256)

12(306.8)

16(408.4)

Internal diameter boiler-flue collar

Connecting Flue Gas PipeInstallation

LegendA Flue vent collar coupling (supplied with boiler)

IMPORTANT

1. Fully insert flue gas adapter inside the flue outlet (if used with stainless steel piping).

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 2-3°). Avoid sharp bends.

2. Connect flue system. Size: 10 in. (250 mm) for models 2.5 and 3.0, 12 in. (300 mm) for models 3.5 and 4.0, 16 in. (400 mm) for models 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.

The boiler flue gas collector vent is not designed to support the weight of the venting system.

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.

Connect flue gas collector with the flue gas pipe using the shortest possible route. Avoid sharp bends.

IMPORTANT

IMPORTANT

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Connecting Neutralization System Installation

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.

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.

WARNINGEscaping 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.

IMPORTANT

IMPORTANT

The neutralization system is available as an accessory.

LegendA Neutralization systemB Hose (supplied with neutralization kit)C Boiler siphon (supplied with boiler)D Hose (supplied with neutralization kit)E On site drainage systemF Boiler flue gas collector Drainage must be lower than the siphon.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Condensate Connection

Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable).

Always connect the drain with a P-trap or siphon to prevent flue gas from escaping into the space.

Connection (external): 7 c in. (7 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.

LegendA Condensate drain (must be able to be inspected)B Open or vented field supplied drainage system

IMPORTANT

IMPORTANT

Note: If the boiler is installed even with the ground, install a condensing drain above the ground max. 2 in. (50 mm).

Note: The ‘amount of condensate” and the “flue gas temperature gross” graphs are independent of each other.

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).

IMPORTANTDo not connect the drain pipe from any other appliance, such as a water softener backwash pipe, to the Vitocrossal 300, CA3 condensate drain pipe.

Am

ount

of

cond

ensa

te

Boiler water return temperature

Flue

gas

tem

pera

ture

gro

ss

Flue gas temp.

at full input

at partial loadFlue gas temp.

Am

ount of

condensate

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Installation Gas Connections

LegendA Field supplied and installed gas shut-off valveB Field supplied and installed unionC Field supplied and installed service gas pressure

regulator (required for all installations)D Field supplied and installed unionE Gas shut-off valveF Built-in low gas pressure switchG Gas pressure regulatorH High gas pressure switchI Test firing valveJ Direct spark ignition burner with VenturiK Fan pressure switch to low fire gas pressure regulator

1* 7 1a in. for individual burner sections2* 7 2b in. for Vitocrossal 300, CA3 models 2.5, 3.0, 3.5 and 4.0 7 3 in. for Vitocrossal 300, CA3 models 5.0 and 6.0

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



LegendA Gas shut-off valveB Low gas pressure switchC High gas pressure switchD Fan pressure switchE Test fire valveF Venturi

Legend1 Burner section 1, lead2 Burner section 2, lag 13 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, done at the section control unit or at the burner control.

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The gas line on the burner meets the requirementsof ASME/CSD-1.

1. Connect gas pipe A to the gas valve. Gas connection: Vitocrossal 300, CA3: 2b in. NPT for models 2.5, 3.0, 3.5 and 4.0, 3 in. NPT for models 5.0 and 6.0. Note: Gas line weld nipples are available as an accessory kit.

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.

Gas Connections (continued)

WARNINGIf test pressure is too high burner and gas fittings may get damaged.

WARNINGEscaped gas may lead to explosion, which could cause severe injuries. Do not vent gas pipe above combustion chamber of boiler.

CAUTIONIf gas pipe contains dirt it is recommended to install a gas filter into the gas pipe.

Installation

For more information refer to the Installation Instructions for gas line weld nipples.

Vitocrossal fuel supply recommendations

- Always read and follow the instructions provided with the gas pressure regulator.

- Install high pressure regulator a minimum of 10 ft. (3.3 m) upsteam of the boiler fuel connection.

- Install one gas pressure regulator per boiler.

- Use a gas pressure regualtor with an outlet size equal to the boiler fuel connection, if a change in pipe diameter is required a concentric reducing coupling should be used.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Installation 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.

IMPORTANTDesign 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.

IMPORTANTMax. 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.

LegendA 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

WARNINGEscaped gas may lead to an explosion, which could cause severe injuries or property damage.

Valve leak test This is a test for checking the leak tightness of the valve and flange connections. It is recommended that this test be included in the scheduled inspection and maintenance procedures.

This test should only be performed by a trained licensedheating 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.

4. Repair any leaks if necessary.

IMPORTANT

Note: Drip pocket shall be installed accordingly to CAN/CSA B149.1 or National Fuel Code ANSI Z223.1 / NFPA 54.

Note: Illustration shown is a generic gas piping configuration, which may vary depending on specific system layout/ requirements.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Installation 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.

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. Refer to page 118 of this manual for further information on water quality.

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.

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.

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 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 floordrain 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

CAUTIONBefore the heating boiler is installed and piped into anexisting 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.

IMPORTANT

Cold water fill pressure must equal expansion tank pressure.

Ensure that there is no leak on any of the connections which are covered by the insulation.

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.

WARNINGFill only suitable water in boiler. Unsuitable water quality may damage boiler.

IMPORTANTOnly use antifreeze specific for hydronic heating systems. Do not use automotive glycol!

Secure the discharge piping from the pressure relief valve with the appropriate hangers or brackets.

IMPORTANT

IMPORTANTFor water quality guidelines refer to page 118.

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Vitocrossal 300 CA3 Series 2.5 to 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.

IMPORTANTThe 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.

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.

ClearancesA 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).

CAUTIONFor 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.

WARNINGIf 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.

IMPORTANTDHW 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.

System Layout

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service System Layout System Layout 1

Vitocrossal 300, CA3 with... - DHW storage tank - one heating circuit without mixing valve

- two heating circuits with a mixing valve

Installation of different heating circuits...

■ high-temp. circuit (radiator heating circuit)

■ low-temp. circuit (under floor heating circuit with 3-way mixing valve)

■ DHW productionThe 3-way mixing valve, built-in to achieve the low-temperature level of the under floor heating circuit, is controlled by an accessory kit for a heating circuit with mixing valve.

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.

IMPORTANT

LegendA Vitocrossal 300, CA3 boiler B Outdoor temperature sensor !C Low temperature heating circuitD High temperature heating circuitE Heating circuit pump F Mixing valve temperature sensor ?G Mixing valve with actuatorH Domestic hot water storage tankI DHW tank temperature sensor %J Expansion tankK Boiler pump/system pump sL *L DHW pump sAM Low loss headerN System supply temperature sensor §/? * When using single speed boiler/system pumps, a hydronic pressure bypass may be required.O Hydronic pressure bypass (if required)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service System Layout System Layout 2

Multiple (up to eight boiler sections) Vitocrossal 300, CA3 with... - multiple heating circuits with mixing valves - low-loss header

Legend

A Vitocrossal 300, CA3 boilerB Low-loss header/common supply temperature sensor §/? on lead boilerC Low-loss headerD DHW storage tankE High temperature heating circuitF Low temperature heating circuitG Hydronic pressure bypass (if required)H Connection to BMS (BACnet/MODbus)I Heating systemJ Variable speed pump control (field supplied)

* Optional accessory (depending on system layout and configuration)

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.

WARNINGIf 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 theinstallation of a temperature tempering valve in the DHW supply line.

Note: When using single speed boiler/system pumps, a hydronic pressure bypass may be required.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Boiler Piping in Heating/Cooling Application

LegendA System supplyB System returnC ValveD Supply check valveE Circulation pumpF Automatic feed valveG Pre-charged expansion tank

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 isconnected 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 flowcontrol valves or other automatic means to prevent gravitycirculation of the boiler water during the cooling cycle.

Check the installation instructions of the chiller manufacturer carefully for additional requirements.

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.

IMPORTANTIn the above system, the circulating pump must be operated from a separate on/off switch - not from the boiler control.

Heating /Cooling unit



Water Chiller

System Layout

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Venting Information

WARNINGThe venting system is approved for indoor installations only. Do not install the venting system outdoors.

WARNINGEnsure that the entire venting system is protected from physical damages. A damaged venting system may cause unsafe conditions.

IMPORTANT

Installation steps (outline)

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 2º-3º based on the vent manufacturer’s system design [example: for a 3º system approx. 2 in. per 3.3 ft. (50 mm per 1 m) on any horizontal venting components].

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.

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.

IMPORTANT

Recommended venting practiceWhen 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.

Venting

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Venting Information (continued)

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 No applicable standards

Galvanized steel Suitable for outdoor use

PVC-DWVSchedule 40

ANSI/ASTM D2661CSA B181.1ULC S102.2ANSI/ASTM D2665, D1785CSA B137.3, B181.2ANSI/ASTM F441

CPVCSchedule 40


ABS-DWVSchedule 40


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

Pipe cement, primer (for combustion air intake pipe)

PVC ANSI/ASTM D2564CSA B137.3

CPVC ANSI/ASTM F493CSA B137.6

ABS ANSI/ASTM D2235CSA B181.1/B182.1

Approved venting materials

CAUTIONDo not use cellular (foam) core pipe material to vent this Vitocrossal boiler.

CAUTIONOn the job site, ensure that non-listed combustion air pipe materials are not inadvertently used instead of listed vent pipe material.

Venting

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting General Venting Information (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:

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.

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.

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.

2....within 4 ft. (1.2.m) horizontally from service regulator vents, electric and gas meters as well as relief equipment.

3....at least 3 ft. (0.9 m) above any forced air inlet located within 10 ft. (3 m).

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.

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.

6.....in areas where condensation may cause problems, such as above planters, patios, or adjacent to windows where flue gases may cause fogging.

7.....within 3 ft. (0.9 m) to the property line (advisable, not mandatory; please check with local building authorities and municipal bylaws).

8.....at a location where ice formation on the ground can present a hazard.

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.

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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Venting Information (continued)

Flashing and storm collar installationFlashings 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

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 left) to order.

Prior to installation, check that the correct single-wall vent parts were ordered and supplied.

Exhaust vent/air intake connection to boilerThe vent connection to the Vitocrossal boiler may require a starter stainless steel adaptor (supplied by others).

Combustion air intakeIf 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.

For exhaust vent pipe material:Do not use any other vent material.

IMPORTANT

Note: For SS venting system order transition adaptors from the above mentioned suppliers.

WARNINGThe 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

M&G / Duraventwww.duravent.com

ICC - Industrial Chimney Co.www.icc-rsf.com

Selkirk Canada Corporationwww.selkirkchimney.com

Novaflexwww.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

METAL-FAB, INC.www.mtlfab.com

The connection set for the combustion air intake kit is available as an accessory.

Room air independent operation (direct vent)

Connecting Combustion Air Intake for Direct Vent

Refer to the installation instructions “combustion air intake kit”.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting

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 listedto 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 68 for two pipe vent installations and page 73 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.

Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material

Requirements for PP(s) and stainless steelThe 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 withlocal 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).

Use only material listed in table on page 60, entitled “Approved venting materials”.

IMPORTANT

IMPORTANT

Side wall vent installations must include a protective screen.

Vent System SuppliersUse 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.


Centrotherm InnoFluewww.centrotherm.us.com

The remaining space surrounding a chimney liner, gasvent, or special gas vent or plastic piping installed withina masonry, metal or factory-built flue shall not be usedto 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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Vent Requirements

WARNINGFailure 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.

CAUTIONDo 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.

Combustion air supply, room air dependent application onlyThe 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.

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.

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.

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 bemade 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.

Venting

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Direct Venting (Two Pipe System)

IMPORTANT

IMPORTANTThe 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.).

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).

Side wall vent termination [stainless steel, CPVC or PP(s)]

* Field fabricated vent riser

Side wall

Support bracket

Termination elbow with screen

*Vent

Caulk

Max. 36 in.(915 mm)

Min. 12 in. (305 mm)

Grade or max. snow level

Min. 36 in. (915 mm)

Stainless steel or plastic mesh

Intake terminal 90o

Min. 12 in. (305 mm)

Exhaust vent terminal 45o

Grade or max. snow level 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)

Min. 12 in. (305 mm)

Min. 2 in. (50 mm)

Air

Vent

Combustion Air Intake Filter (field supplied)

A combustion air inlet filter may be installed at any point in the combustion air inlet ducting (field supplied).Sized for 16” X 25” X 1” high performance furnace filteracceptable filters include 3M 1000, 1500, or 1900 series filters or equivalent. Ensure location of installation allows for adequate services clearance for filter inspection and maintenance.Refer to filter manufactures instructions for cleaning replacement intervals, filter care, etc.Do not decrease the combustion air intake diameter, the diameter must be maintained through the combustion air intake ducting.Using combustion air filters remove dust particles from supplied combustion air. It is the responsibility of installing contractor/designer or engineer to make sure any impurities contain in combustion air supply to the boiler, that can affect the operation or life expectancy of the components, are removed and dealt with.Note: The boiler combustion air inlet connection is not designed to support the weight of the combustion air ducting, filter or filter housing ensure that the combustion air ducting is properly supported.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Side Wall Venting

IMPORTANTFor PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).

Side wall vent termination [stainless steel or PP(s)]

Min. 12 in. (305 mm)

Exhaust vent terminal 90o


* Field fabricated vent riser

Side wall

Support bracket

Termination elbow with screen

*Vent

Caulk

Max. 36 in.(915 mm)

Min. 12 in. (305 mm)


Flue

Min. 2 in.

Max. 36 in.(50 mm)

(915 mm)

Venting

Component Installation GuideFlashing and storm collar installationFlashings 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.

Elbow - Equivalent Length

Equivalent Length

Elbow size 7 4 in. (100 mm) 6 in. (150 mm), 8 in. (200 mm), 10 in. (250 mm), 12 in. (300 mm), 14 in. (350 mm), 16 in. (400 mm)

45º 1 ft. (0.3 m) 5 ft. (1.5 m)

90º 1.6 ft. (0.5 m) 10 ft. (3 m)

Note: If flexible vent or flexible air-intake pipe are used, the total max. equivalent length will be reduced by 25%.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Vent Termination Location Requirements - Vertical

WARNINGVent 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.

IMPORTANT

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.

A masonry chimney flue may be used to route the venting system only if no other appliance is vented in the same flue.

For flat roof applications

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.).

For sloped roof applicationswith distance b greater than 18 in. (450 mm)

For sloped roof applications with distance b less than 18 in. (450 mm)

Legenda minimum 18 in. (450 mm)b <18 in. (450 mm)

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).

Installation of Support System - PP(s)

IMPORTANT

BracingContact 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.

Ensure that the venting system is properly supported; the boiler is not designed to support the weight of the venting system.Vent system suppliersTo order approved PP(s) vent system contact the following suppliers.


Centrotherm InnoFluewww.centrotherm.us.com

IMPORTANTFor exhaust vent pipe material:Use only ULC S-636 / UL 1738 vent material.

b

a

a

b

a

68

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Two Pipe System - Vertical Exhaust/Vertical Air Intake

Flue

Air

a - Equivalent exhaust lengthb - 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 (b) ft. (m) 66 (20) 131 (40) 50 (15) 66 (20)Max. total equivalent length (a+b)* ft. (m) 198 (60) 198 (60) 115 (35) 198 (60)



Combustion air intake diameter in. (mm) 16 (400) 16 (400)Exhaust vent diameter in. (mm) 16 (400) 16 (400)Max. combustion air intake length (b) ft. (m) 198 (60) 164 (50)Max. total equivalent length (a+b)* ft. (m) 198 (60) 198 (60)

* A minimum of 20 ft. (6 m) of equivalent exhaust vent length must be included in the equivalent vent length (a+b) calculation.Note: If flexible vent or flexible air-intake pipe are used, the total max. equivalent length will be reduced by 25%.




Combustion air intake diameter in. (mm) 10 (250) 12 (300) 10 (250) 12 (300)

Exhaust vent diameter in. (mm) 10 (250) 12 (300) 10 (250) 12 (300)Max. combustion air intake length (b) ft. (m) 66 (20) 99 (30) 33 (10) 99 (30)Max. total equivalent length (a+b)* ft. (m) 99 (30) 198 (60) 52 (16) 198 (60)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Two Pipe System - Vertical Exhaust/Vertical Air Intake (continued)

LegendA Support systemB FlashingsC Exhaust with screenD Combustion air intake with screen

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).

IMPORTANT

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

Vertical Vent Installation Sloped Roof

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Two Pipe System - Horizontal Exhaust/Horizontal Air Intake

Flue

Air

Min. 36 in.(915 mm)


Horizontal intake and exhaust


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 (b) ft. (m) 50 (15) 66 (20) 50 (15) 50 (15) 131 (40)Max. total equivalent length (a+b)* ft. (m) 99 (30) 198 (60) 66 (20) 149 (45) 198 (60)









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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Two Pipe System - Vertical Exhaust/Horizontal Air Intake

Flue

Air


Horizontal intake and vertical exhaust


Combustion air intake diameter in. (mm) 12 (300) 12 (300) 12 (300) 14 (350)Exhaust vent diameter in. (mm) 12 (300) 14 (350) 12 (300) 14 (350)Max. combustion air intake length (b) ft. (m) 66 (20) 131 (40) 50 (15) 66 (20)Max. total equivalent length (a+b)* ft. (m) 198 (60) 198 (60) 115 (35) 198 (60)









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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Individual Burner Intake Ducting

The combustion air intake ducting equivalent length must be calculated based on the single combustion air intake pipe with the longest equivalent length (as shown in the illustration with grey fill).

Refer to pages 66, 68, 70 and 71 to determine maximum equivalent lengths. For roof and vent spacing refer to page 69.

For combustion air intake duct connection to the boiler, refer to the “Combustion Air Intake Kit” Installation Instructions.

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Flue

Air

RoomCombustion Air Opening

Air

Venting Options - Stainless Steel/PP(s) Single Pipe System - Vertical Exhaust/Room Air Dependant

a - Equivalent exhaust length

Vertical exhaust/room air dependant


Exhaust vent diameter in. (mm) 12 (300) 14 (350) 12 (300) 14 (350)

Max. vent equivalent length ft. (m) 198 (60) 198 (60) 198 (60) 198 (60)



Exhaust vent diameter in. (mm) 16 (400) 16 (400)

Max. vent equivalent length ft. (m) 198 (60) 198 (60)




Exhaust vent diameter in. (mm) 10 (250) 10 (250) 12 (300)

Max. vent equivalent length ft. (m) 198 (60) 108 (33) 198 (60)

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FlueAirAir

RoomCombustion Air Opening

Single Pipe System - Horizontal Exhaust/Room Air Dependant

a - Equivalent exhaust length


Horizontal exhaust/room air dependant






Exhaust vent diameter in. (mm) 16 (400) 16 (400)

Max. vent equivalent length ft. (m) 198 (60) 198 (60)






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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Venting Options - Stainless Steel/PP(s) Multiple Boiler Installations

Horizontal vent termination

Vertical vent termination

36 in. min.(915 mm min.)

Note: 36 in. (915 mm) minimum distance apart for horizontal vent terminations.

6 in. min. (150 mm min.)

4 in. min.(100 mm min.)

Note: 4 in. (100 mm) minimum distance apart for vertical vent terminations.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Service Information Service Equipment

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

Cleaning supplies Plastic hand brush Cleaning/service brush Vacuum cleaner Clean rags

Testing/analysis equipment(use only calibrated equipment)

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 0ºF to 250ºF

(0ºC to 121ºC). d in. NPT male to ¼ in. barb adaptor fitting, as well

as tubing for pressure measurement.

Technical informationThe following is a list of literature applicable to the Vitocrossal 300, CA3 boiler:

Installation/Service Instructions Operating Instructions Technical Data Manual

For installation of the heating system, please refer also to the technical literature of other Viessmann 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 206 of these instructions.

Order replacement components from your Viessmann distributor.

CAUTIONUse only original Viessmann recommended components when replacing defective parts. Installation of incorrect replacement parts can cause hazardous operation and will void warranty.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Important Regulatory and Installation Requirements

Instructing the system userThe 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-upInitial 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 equipmentThe 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.

Technical literatureLiterature applicable to all aspects of the Vitocrossal 300, CA3:- Technical Data Manual- Installation and Service Instructions- Operating Instructions- Wiring diagrams

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 249 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.

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.

General Service Information

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Service Information

Checking the high limit safety cut-out settingThe 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.

■ Shut down the heating system.■ Ventilate boiler room.■ Close all doors in the living space

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.

Target groupThese 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.RegulationsObserve 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

Safety Instructions

■ 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

WARNINGEscaping gas can lead to explosions which may result in serious injury.

WARNINGFlue gas can lead to life threatening poisoning.

Auxiliary components, spare and wearing partsNote: 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.

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.

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 temperature-operated 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 (per boiler section) that when activat-ed 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 workNote: Repairing components that fulfil a safety function

can compromise the safe operation of your system. Replace faulty components only with original Viessmann spare parts.

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Fixed High Limit test procedure:1. Use the emission test switch on each boiler section to generate call for heat.

2. As described in the table on page 190, 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 of the applicable boiler section, the burner will start.

4. Gradually and slowly throttle the water flow to the boiler.

5. Observe temperature on the relative GW6C service display.

6. Once the temperature reached the fixed high limit setting, burner control will have a hard lock out with F F1 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).

General Service InformationSafety Instructions (continued)

Menu item “6“ is used to change the following operating parameters: (see page 190 for more detail)

Sub-menu Item

Parameter Units/Scale Factory set condition

1 Maximum operational input % of rated input 100%

2 Gas type 0=NG (natural gas)1=LPG (liquid propane gas)

0

3 Not assigned -- --

4 Maximum boiler water temperature from 41°F to 260°F (5°C 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 pause1=integral method

1

0 Reset all operating parameters to their factory set condition.

-- --

Note: Each boiler section is equipped with its own fixed high limit. Each fixed high limit must be tested individually.

Refer to Vitocrossal 300 CA3 Operating Instructions.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceFilling the Heating System with Water and Ventilating

1. Fill Vitocrossal 300, CA3 with fully softened water.

2. Enter the fill quantity, water softness and pH-value in the chart provided on page 248.

3. Before filling push the actuator release button and open each isolation valve (located near the return header of each boiler section).

4. When fill is complete push the actuator release button and close each isolation valve (located near the return header of each boiler section).

Filling Condensate Trap with Water

IMPORTANTSee page 118 for water quality requirements.

Checking the Type of Gas

IMPORTANTThe heating system is equipped for operation with natural gas. Switching over to another type of gas is not possible.

1. The burners are factory set for operation with natural gas.

2. Record gas type in record (on page 249).

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.

Push actuator releasebutton

To close valve

Valve closed

To open valvePush actuator releasebutton

Valve open

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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, refer to page 99 for NG or page 101 for LPG.

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 116).

Operating the System Service

Commissioning the system

See the 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. (NG) and 10-14 “w.c. (LPG).

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.

WARNINGFailure 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.

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.

Gas type characteristicsThe Vitocrossal 300 CA3 boiler is for use with gases whose characteristics fall within the following ranges.

Natural Gas Liquid Propane Gas

Heating value (gross) Btu/ft3 970 to 1100 2466 to 2542

Specific gravity 0.57 to 0.70 1.522 to 1.574

Ultimate carbondioxide (CO2) % 11.7 to 12.2 13.73 to 13.82

See the control section of the Installation Instructions and neutralizing system Operating Instructions.

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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.

With / , you can switch between codes. After you have scrolled through all the codes,

a message appears to end operations.

Operating the System (continued)

IMPORTANT

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

Service

LegendA System and lead boiler section 1 control unitB Boiler section 2 control unit C Boiler section 3 control unit (5.0 and 6.0 only)

LegendA System and lead boiler section 1 control unitB Boiler section 2 control unit

Boiler model 2.5 and 3.0

Boiler model 3.5 to 6.0

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Operating the System (continued)

Service

Function Group Coding

“Connection at plug 29” “General” 4D“Viessmann system number” “General” 98 “With LON communication module: LON Participants monitoring” “General” 9C“With LON communication module” (lead control unit is fault manager) “General” 79“Central control of heating circuits” “General” 7A“Viessmann system number” “General” 98“With LON communication module: Monitoring LON participants” “General” 9C“Storage tank heating, hysteresis” “DHW” 55

Adjusting the coding Check all addresses in Coding level 1 and adjust if required. See “Coding Levels”.

Check the following coding addresses in Coding level 2 and adjust accordingly.

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 levels.

See Chapter “Coding Levels” for procedural steps and overviewon code setting.

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.

Burner will start up after a 3 min delay.

IMPORTANT

IMPORTANT

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Adjusting the Heating Curve

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

Example for outdoor temperature 5°F (−15°C)A Underfloor heating system, slope 0.2 to 0.8B Low temperature heating system, slope 0.8 to 1.6C Heating systems with a boiler water temperature in

excess of 167°F (75°C), slope greater than 1.6

LegendA Boiler water temperature or supply temperatureB Outdoor temperatureC Set room temperatureD Heating circuit pump “Off”E Heating circuit pump “On”

Selecting the set room temperatureIndividually 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 Vitocrossal 300 CA3 Operating Instructions.

Standard set room temperature

Adjustment of the standard set room temperature from 68°F to 79°F (20°C to 26°C).

Service

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Adjusting the Heating Curve (continued)

Service

Refer to the Vitocrossal 300 CA3 Operating Instructions.

LegendA Boiler water temperature or supply temperatureB Outdoor temperatureC Set room temperatureD Heating circuit pump “Off”E Heating circuit pump “On”

Changing the standard set room temperatureReduced set room temperature

Adjustment of the reduced set room temperaturefrom 37°F to 52°F (3°C to 14°C).

LegendA Changing the slopeB Changing the shift (vertical parallel offset of the

heating curve)

Outdoor temperature

Boi

ler w

ater

or

supp

ly tem

pera

ture

Changing the slope and shiftIndividually adjustable for each heating circuit.

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.

Example: Heating curve setting with slope 1.5:

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Integrating the Control Unit into the LONService

A B C D E

Multiple boiler systemSet coding “01:2” in the “Boiler” group.

Multiple boiler systemSet coding “01:2” in the “Boiler” group

Multiple boiler systemSet coding “01:2” in the “Boiler” group.

-- --

Boiler number 1Coding “07:1” in the “Boiler” group

Boiler number 2Set coding “07:2” in the “Boiler” group.

Boiler number 3Set coding “07:3” in the “Boiler” group

-- --

Number of connected boilers. Set coding “35:1” to “35:8” in the “Cascade” group.

-- -- -- --

Participant No. 1.Coding “77:1” in the “General” group.

Participant No. 2.Coding “77:2” in the “General” group.

Participant No. 3.Set coding “77:3” in the “General” group.

Participant No. 99. Participant No. 10.Coding “77:10” in the “General” group.

Control unit is fault manager.Coding “79:1” in the “General” group.

Control unit is not fault manager.Coding “79:0” in the “General” group.


Appliance is fault manager.


Control unit transmits time.Coding “7b:1” in the “General” group.

-- -- Appliance receives time.

Control unit receives time.Set coding “81:3” 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 number, coding “98:1” in the “General” group.



-- Viessmann system number, coding “98:1” in the “General” group.

LON Participant fault monitoringCoding “9C:20” in the “General” group.



-- LON Participant fault monitoringCoding “9C:20” in the “General” group.

Remove terminal end resistor on A to carry on LON connection

The LON communication module is factory installed. Vitotronic 200-H:

The LON communication module (accessory) must be plugged in.

Refer to the Vitotronic 200-H Installation and Service Instructions.

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.

LegendA Boiler section 1/ lead control unit B Boiler section 2/ lag control unit 1C Boiler section 3/ lag control unit 2 (CA3 5.0 and 6.0 only)D Vitocom 100 LAN 1 with integrate LON terminal end resistorE External control unit (Vitotronic 200-H HK1B)

Note: Cascade combination of CA3 boilers cannot exceed 8 boiler sections.

Vitotronic 300 GW6C for CA3 2.5, 3.0, 3.5 and 4.0

Vitotronic 300 GW6C for CA3 5.0 and 6.0

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Integrating the Control Unit into the LON (continued)

Service

Carrying out a LON participant checkThe 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.

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Disconnect power and ensure system is shut down during any service work on the burner.

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.

IMPORTANT

1. Remove top panels.

2. Remove panels on the right side (service side) of the boiler. In order to remove the burner, dismantle the following:

3. remove upper frame profile.

4. Remove upper side frame profile for 3.5 to 6.0 only). If applicable, only on the burner that is being removed.

5. If a lifting device is to be installed, remove lower side panel.

Service Preparing for Service Work on the Boiler and Burner

CA3 2.5 and 3.0

CA3 3.5 to 6.0

1. Remove the top panels.

2. Remove the panels from the right side (service side) of the boiler.

Note: When uninstalling the burner, remove the following components as well

3. Remove top frame profile.

4. To install lifting gear, remove the lower side panels.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Preparing for Service Work on the Boiler and Burner (continued)

Burner Combinations

Burner Input MBH

Boiler model Section 1 (lead) Section 2 (lag 1) Section 3 (lag 2)

2.5 1250* 1250* --

3.0 1500* 1500* --

3.5 1500 2000 --

4.0 2000 2000 --

5.0 1500 1500 2000

6.0 2000 2000 2000

Section 1

Section 2

Section 3

Front of boiler

Rear of boiler

Burner Identification

* Compact burner models

90

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceReducing 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 D for the desired maximum heating output.

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.

8. Press button R G. A system reboot will be initiated.

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Checking Static and Connection Pressure Service

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 249).

WARNINGEnsure that there is no open flame in the room.

WARNINGNever 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.

IMPORTANTThe 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.

A CO2 measurement (see page 93) must be taken before and after working on gas appliances to eliminate risks tohealth and to guarantee the satisfactory condition of the system.

IMPORTANT

Supply pressure for NG/LPG 1. Start the burner

Note: For commissioning, see page 93. 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. Value must be as per the chart below:

Note: The supply pressure should be between 4 “w.c. and 14 ”w.c. for NG and 10” w.c. to 14” w.c. for LPG. 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 maintenance record (on page 249).

4. Close the gas shut-off valve.

5. Remove the pressure tester and close test nipple A.

Supply pressure with: Corrective action

Natural gas Liquid propane gas

under 4”w.c. under 10”w.c. Do not attempt adjustment. Call local gas utility

4 to 14“w.c. 10 to 14”w.c. Start up boiler.

over 14”w.c 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.

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2. Check the rotary damper setting when burners are off. The rotary damper 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 damper during the start-up phase. The rotary damper windows B must nearly close for approx. 5 sec. The scale ring D must be set as follows during this time:

ServiceChecking the Rotary Damper Setting

Boiler model Burner model Rotary damper setting

2.5 and 3.01.25 MMBTU Not equipped

1.5 MMBTU Not equipped

3.5 to 6.01.5 MMBTU 20° (close) 0° open

2.0 MMBTU 20° (close) 0° open

Checking the functioning of the burner 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 operationServomotor moves to 105°, levers and rods move to the left. Valve A is opened.

Turning burners offServomotor moves to setting “0”, valve B 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.

Checking the Burner Damper Setting

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceMeasuring CO2 Content

Preparing for measurement

IMPORTANTWhen adjusting a burner only this one burner may be inoperation. The other boiler unit burners must be at standstill. Take measurement readings of burners one after the other.

CO2 Test at the upper heating input1. 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 249).

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

Boiler models Burner models Permissible CO2 content (%)


2.5 and 3.0

1.25 MMBTU 8.8 - 9.2 10.8 - 11.0

1.5 MMBTU 8.8 - 9.2 10.8 - 11.0

3.5 to 6.0

1.5 MMBTU 8.8 - 9.2 10.8 - 11.0

2.0 MMBTU 8.8 - 9.2 10.8 - 11.0

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceMeasuring CO2 Content (continued)

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.

Measuring CO2 at lower heating output

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 249). 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, 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.

CO2 content in partial load must always be at least 0.6% lower than in full load.

IMPORTANT

Boiler models Burner models Permissable CO2 content (%)


2.5 and 3.0

1.25 MMBTU 8.1 - 8.4 8.9 - 9.3

1.5 MMBTU 8.1 - 8.4 8.1 - 8.4

3.5 to 6.0

1.5 MMBTU 8.1 - 8.4 8.1 - 8.4

2.0 MMBTU 8.1 - 8.4 8.5 - 8.9

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceDisplaying Ionization Current

1. Press button S for approx. 2 sec., „ “ will blink.

2. Press button until “5” appears under Service.

3. Press button S. “5” will appear under Status.


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 test-switch.

7. Take ionization current reading.

8. Record the measurement reading in the maintenance record on page 249.

9. Press button S approx. 2 sec, „ “ will blink.


11. Press button S. “5” will appear under Status.


13. Press button S. The operating status indicator appears again.

IMPORTANT

Ionization current must be queried via the burner control unit. An ionization current measurement with Testomatic Gas or a multimeter is not possible.

IMPORTANT

Turning the System Off

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.

1. Turn off main power switch or power supply voltage and ensure against being unintentionally switched on again.

WARNINGPower supply voltage is dangerous and may cause life-threatening injury. The system must be disconnected from the power supply before maintenance work is performed.

2. Close central gas shut-off valve.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service

Dismantling the Burner

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.

2. Remove 6 nuts.

IMPORTANTPlease observe chapter “Preparing for service work on the boiler and burner” on page 88.

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Secure lifting mechanism chains at 3 points A on the frame of the upper burner section.

ServiceDismantling the Burner (continued)

1. Lift upper burner section with lifting mechanism.

2. Swing upper burner section to the side.

Refer to the Installation Instructions for lifting device.

IMPORTANTA 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.

1. Remove 8 nuts from the combustion chamber cover plate.

2. Lift out mounting plate with burner tube.

Installing the lifting device

For CA3 2.5 and 3.0 For CA3 3.5 to 6.0

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Burner Parts

LegendA Burner chassis B Air pressure monitor 1C Air pressure monitor 2D Display and programming unitE Gas valveF Gas connector pipeG Gas pressure switchH Rotary damper with servomotorK Venturi mixing tubeL Burner fanM Burner gauze assemblyN Ignition electrode block O Burner control unitP Mains filter unit

Service

LegendA Burner frameB Air pressure switch 1

C Air pressure switch 2D Display and programming unitE Gas valveF Gas supply pipeG Gas pressure switchH Solinoid valve (not shown)I Venturi mixing pipe J Burner fanM Burner gauze assemblyN Ignition electrode blockO Burner control unitP Mains filter unit

1.5/2.0 MMBH (CA3 3.5 to 6.0)1.25/1.5 MMBH (CA3 2.5 and 3.0)

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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 117. Note: If fault code “F b7” is displayed, check the coding card.

Refer to the Service Instructions.

Coding Card on Burner Control Unit

Display and Programming Unit of Burner Control Unit




4. Install new display and programming unit in reverse order.

5. For further steps, see chapter “Further assembly” on page 117.

NG coding cardBoiler Model Burner model Coding card part #

CA3 2.5 and 3.01.25 MMBTU 78636691.5 MMBTU 7863668

CA3 3.5 to 6.01.5 MMBTU 78662762.0 MMBTU 7862577

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Burner Control 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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Fuel Conversion NG to LPG

Natural Gas (NG) to Liquid Propane Gas (LPG)

5167 212 (This unit is equipped for Propane Gas)

- Apply new LPG label over the existing NG label located on the gas valve.

5167 295 (This appliance has been field convertedto Liquid Propane Gas)

- Apply next to CSA Rating Plate.

5285 200 (Conversion Report Form)

- Complete form and Fax or E-mail to Viessmann. Keep a copy for your own record.

Conversion Labelling

LPG coding card

Boiler Model Burner model B coding card ID

CA3 2.5 and 3.0

1.25 MMBTU 50921.5 MMBTU 5093

CA3 3.5 to 6.0

1.5 MMBTU 50902.0 MMBTU 5091

Service

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Fuel Conversion NG to LPG (continued)

WARNINGA gas leak may lead to an explosion. Leak test the reconnected gas line and gas valve connections.

CAUTIONUsage of leak detection spray may lead to a malfunction. Avoid contact between leak detection spray and electrical contacts.

Boiler model Burner model A orifice LPG

CA32.5 and 3.0

1.25 MMBTU 7 14.8 mm

1.5 MMBTU 7 14.8 mm

CA33.5 to 6.0

1.5 MMBTU 7 14.8 mm

2.0 MMBTU 7 17.4 mm

Torque gas valve screws to 13.3 lb.in (1.5 Nm)

*Note: The orifice champfer faces the gas valve.

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1. Close the gas shut-off valve.2. Switch OFF the main circuit breaker or the power supply and safeguard against unauthorized reconnection.

3. Remove the boiler left side panels (see page 88).

4. Disconnect power cable with plug fÖ. Then disconnect the burner cables with plugs §A/§B, aGA/aGB, fA, gD, lÖ and in addition to plug avG from the burner control unit and pull out of the burner casing.

Service Burner Interface Panel

WARNINGMains voltage can be extremely dangerous. For maintenance work, isolate the system from the power supply.

CA3 3.5 to 6.0

CA3 2.5 and 3.0

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service 3A and 3B Boiler Temperature Sensor Description

3A sensor (NTC 10k) terminals 1 & 2

3B sensor (NTC 20k) terminals 3 & 4

Temperature

Res

ista

nce

in k

ohm

s

Temperature

Res

ista

nce

in k

ohm

s

3A sensor (NTC 10k)

3B sensor (NTC 20k)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Boiler Water Temperature Sensor

Note: There is a boiler water temperature sensor located on each boiler section.

1. Remove spring clip from the sensor well and set aside.

2. Remove the boiler water 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.

5. Reinstall spring clip.

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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 15A/15B.

4. Connect new sensor to sensor cable plugs 15A/15B and install into the sensor well.

5. Reinstall spring clip.

Temperature

Res

ista

nce

in k

ohm

s

Note: The sensor is located in each boiler section and the connecting plug is located at the burner control unit, for that boiler section.

Service

LegendA Temperature sensor B Connecting plugs 15A/15BC Burner control plug

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Manual Reset Limits

Temperature limit switchIf 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.

LegendA Probe wellB Supply water temperature limit switchC Flue gas temperature limit switch

IMPORTANTThe switches are preset fom the factory, do not adjust.

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Gas Valve

Note: Reinstalled gas valve in the same orientation as originally installed.

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.

AssemblyAssembly 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 117.Note: Never interchange the connecting cables of the two gas pressure switches (GDW 1 and GDW 2).

WARNINGEscaping gas leads to a risk of explosion.Check the fitting for gas tightness.

CAUTIONThe use of leak detection spray can result in faulty operation. Leak detection spray must not come into contact with electrical contacts.

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 194) with fault indicators “F F5” and “F F7”. The fault shutdown can be released by pressing the reset button R.

Air Pressure Switches

Boiler model Burner model Setting value LDW1

CA32.5 and 3.0

1.25 MMBTU 0.4”w.c. (1 mbar)

1.5 MMBTU 0.4”w.c. (1 mbar)

CA33.5 to 6.0



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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 pre-aeration 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.

Air Pressure Switches (continued)

Service

* Equipped with a non adjustable Kromschroder valve.

Boiler model Burner model Setting value LDW2

CA32.5 and 3.0

1.25 MMBTU 3.6”w.c. (9 mbar)


CA33.5 to 6.0


2.0 MMBTU preset*

1.25 MMBTU and 1.5 MMBTU

2.0 MMBTU

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Compensation lines (for CA3 3.5, 4.0, 5.0 and 6.0)Replacement lines must be cut to length. See following table for required length.

Line 7 in. (mm) Burner model 1.5/2.0 MMBTULength in. (mm)

A a (6) 7 (200)

B d (4) 6/9 (150/230)

C d (4) 1e (35)

D d (4) 10f (270)

E d (4) 15/17 (380/430)

F d (4) 15/13c (380/350)

G a (6) 13c (350)

Compensation lines (for CA3 2.5 and 3.0)Replacement lines must be cut to length. See following table for required length.

Line 7 in. (mm) Burner model 1.25/1.5 MMBTULength in. (mm)

1 a (6) 8f (220)

2 a (6) 1 (48)

3 a (6) 2 (72)

4 d (4) 8a (209)

5 a (6) 19a (490)

6 d (4) 12 (326)

7 d (4) 11 (302)

8 a (6) 10 (255)

9 a (6) 21 (533)

LegendA Gas trainB Air pressure switch 1C Air pressure switch 2D Solenoid valveE Venturi mixing pipeF Burner frameG Gas feed nozzles

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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 117.Note: Set the new air pressure switch to exactly the same value as that of the replaced air pressure switch.

LegendA 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 settingsBoiler model CA3 2.5 and 3.0 CA3 3.5 to 6.0Burner model 1.25

MMBTU1.5

MMBTU1.5

MMBTU2.0

MMBTULDW1 mbar

(“w.c.)1

(0.4)1

(0.4)1

(0.4)1

(0.4)LDW2 mbar

(“w.c.)9

(3.6)9

(3.6)9

(3.6)preset*

Only for Dungs gas pressure switches.

All gas pressure switches are Dungs unless otherwise noted.

Service

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).


* Equipped with a non adjustable Kromschroder valve.

Ignition Unit


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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.6. Install new rotary damper, air pressure switch and servomotor in reverse order.7. For further steps, see chapter “Further assembly” on page 117.

IMPORTANTFor CA3 models 3.5 to 6.0

An incompletely opened rotary damper can cause malfunctions or indicate incorrect adjustment of the servomotor. The rotary damper must be fully open whenthe burner is off and during operation. If necessary, adjust it via the articulated rod. See service instructions for servomotor settings.

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.


Replacing the Solenoid Valve

1. Undo the hose clips and remove the hoses. Unscrew 2 plastic brackets from the 2/2 directional valve.

2. Unscrew 2 fixing screws and remove 2/2 directional valve.

Assemble in reverse order. Torque: 1.5 NmScrew the plastic brackets into the new 2/2 directionalvalve. Fit the hoses and secure with hose clips (observe the mark on the valve: 1 left, 2 right).Note: Only for boiler models 2.5 and 3.0.

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Checking and Cleaning the Burner Tube

1. Remove the electrodes (if required).

2. Undo 6 screws from the insulation ring. Torque when installing: 13 lb.in (1.5 Nm.)

3. Remove the insulation ring.

4. Unscrew the burner gauze assembly. You can now vacuum or replace the burner gauze assembly. Torque when installing: 7.5 lb.ft (10 Nm.)

5. Replace all gaskets. Reassemble burner tube and burner in reverse order. Torque: 7.5 lb.ft (10 Nm).

6. Remove the insulation ring.

WARNINGGas leakage can lead to risk of explosion. Close gas shut-off valve.

WARNINGContact with hot surfaces can lead to burn injuries.Undertake work on the burner only when the system is cold.

CAUTIONScratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber.

CAUTIONContamination 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.

CAUTIONImproperly executed exchange of the burner tube can lead to contamination of the combustion chamber. Ensure that the combustion chamber is maintained free of insulation fi bres.

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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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: 4.4 lb.ft (6 Nm).

Cleaning the Burners

IMPORTANTClose the central gas shut-off valve for all dismantlement work on the burners.

For dismantling the burners see from page 96.

LegendA Combination gas valveB Gas connector pipeC Fitting at gas connector pipeD Venturi-mixing tubeE FanF Flame tube

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.

6. Reassemble in reverse order.

IMPORTANTEnsure correct positioning of gasket between fan housing and burner plate. Replace gasket if damaged.

WARNINGRisk of explosion due to gas leakage. Check for gas leakage at screws and the gasket between the fan housing and the burner plate.

Service

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CAUTIONScratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber.

CAUTIONScratches 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

Checking gaskets and thermal insulation parts 1. Check gaskets and the sealing rope for damage.

2. Check the thermal insulation components for possible damage.

3. Replace any damaged parts.

1. Clean the combustion chamber by vacuuming loose debris out.

2. Remove embedded sediment from the stainless steel heat exchanger surface by thoroughly rinsing with water or solvent free cleaning agents such as citric acid based cleaners. Consult a cleaning agent manufacturer for a suitable product. Avoid getting the refractory wet during cleaning. Note: Discoloration of the heat exchanger surface is the normal result of the combustion process. It has no impact on the functionality or the longevity of the heat exchanger.

3. Use a non-metallic brush if necessary, with a gentle brushing motion to remove the embedded sediment. It is not recommended to use chemicals to clean the heat exchanger surface.

4. Flush the combustion chamber with water until it runs clear through the condensate trap.

5. Remove and clean out any accumulated debris from condensate trap. Reinstall condensate trap. See page 116 for details.

Cleaning the combustion chamber and heating surfaces

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WARNINGWorking on pressure loaded parts can be dangerous. Connections around the heating water should only be opened if the boiler is unpressurized.

CAUTIONUnder-pressure in the boiler can lead to material damages. Only empty boiler with open ventilation with a suction pump.

IMPORTANT

Service

Cleaning of Condensate Drainage System

Checking Heating Water Connections for Leakage

Ensure that connections for control equipment and minimum pressure monitor (low-water indicator) are also leakage-free.

IMPORTANTIf 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. 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. If contaminated - rinse the neutralization unit with tap water.

3. Add granulate as marked.

IMPORTANTThe granulate is consumed as it neutralizes the condensate. The red marking indicates the minimum filling level.

See Neutralization Unit ”Installation Instructions”.

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.

Note: Clean the inside of the condensate drain system at least annually.

1. Pull drain or cleaning hose D off.

2. Clean the inside of the condensate drain system (hose, pipe).

3. Clean the neutralizing system (if installed) in accordance with the manufacturer‘s instructions.

See Neutralization System Operating Instructions.

Note: You can obtain the neutralizing granulate from Viessmann.

4. Release and flush lower part C of siphon cup B.

5. Fill lower part C of siphon cup B with water and reassemble.

6. Install hose A of the neutralizing system to the siphon.

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Checking for Flue Gas Leakage

Service

IMPORTANTGaskets 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.

Check flue gas collector and boiler body for leakage.

Automatic Leakage Test for Valves of the Combination Gas Valve

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.

WARNINGRisk of explosion due to gas leakage. Check for gas leakage at the gauge connections.

Further Assembly and Commissioning

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.

WARNINGEscaping gas leads to a risk of explosion.Check the fitting for gas tightness.

CAUTIONFailure 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.

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1. Insert and tighten new gaskets at all detached on-site connections.


3. Check sealing points at input side of the combination gas valve for leakage.

4. Put boiler into operation (see page 81).

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.

Checking On-site Gas Connections for Leakage

WARNINGRisk of explosion due to gas leakage. Check for gas leakage at the gauge connections.

CAUTIONUse of leak detection spray can lead to operational malfunctioning. Leak detection spray must not come into contact with electrical contacts.

Taking Final Measurement Reading

1. Take CO2 measurement reading after each burner dismantling in accordance with the items beginning from pages 93 and 94.

2. Record the measurement readings in the maintenance record on page 249.

Checking the Water Conditions

Total output (MBH) Total Hardness (ppm of CaCO3)

> 2050 2

Water Quality

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.

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.

The pH value of the heating water should be between 8.2 and 9.5Only fill the boiler with water that conforms with water quality guidelines of VDI 2035-1.

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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.

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.

Service

In systems > 170 MBH (50 kW), install a water meter to capture the amount of fill and top-up water. Enter the volume of fill water and the water hardness into the boiler maintenance checklists.Operating information:

During expansion or repair work, only drain the pipework sections which are crucial.

Check, clean and activate filters, dirt traps and other blow-down or separating facilities in the heating water circuit frequently after commissioning and in new installations. Thereafter check and maintain as required, depending on the type of water treatment applied (e.g. water softening).

If the heating system is filled with fully softened water, no other measures for start-up are required. If the heating system is not filled with fully softened waterbut with water which fulfils the requirements given in the table above, the following should also be considered for commissioning:

Start the system step by step with a high heating water flow rate, starting with the lowest boiler output. This prevents localized concentration of lime scale deposits on the boiler heating surfaces.

In multiple boiler systems, start all boilers simultaneously to prevent the entire lime scale deposit settling in the heat exchanger of just one boiler.

Where water treatment is required, treat the first fill of the heating system prior to start-up. This also applies to any subsequent filling, e.g. when adding top-up water or after a repair, or for any system expansion. The build-up of lime scale deposits on the heating surfaces will be minimised if these instructions are followed.

Checking the Water Conditions (continued)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceChecking the Water Conditions (continued)

Avoiding damage caused by water corrosionThe corrosion-resistance on the heating-water side offerrous materials used in heating systems and heatgenerators depends on the absence of oxygen in theheating water. The oxygen that enters the heating system upon initial and subsequent filling reacts with the system materials without causing damage.The characteristic blackening of the water after a certainoperating time is a sign that there is no longer any free oxygen.

During operation, oxygen can enter due to: Open vented expansion vessels due to flow through Negative pressure in the system Through permeable components

Correctly sized sealed unvented systems operating at the correct pressure, e.g. systems with expansion vessel,offer good protection against the ingress of airborneoxygen. The pressure must be above the pressure of the ambient atmosphere at all times during operation and at every point in the heating system, including the suction side of the pump. Check the precharge pressure of the expansion vessel at least during the annual service. Avoid the use of components permeable to gas, e.g. permeable plastic pipes in underfloor heating systems. If they are used, system separation should be provided. This system separation must separate the water flowing through the plastic pipes from other heating circuits,e.g. from the boiler, by the provision of a corrosion resistant heat exchanger. No other protective measures against corrosion are necessary in corrosion-resistant closed hotwater heating systems in which the previous points have been taken into account. However, take additional precautions where there is a risk of oxygen ingress,for example by adding oxygen binder sodium sulphite5 to 10 ppm (5 to 10 mg/L) into the excess. The pH value of the heating water should be 8.2–9.5.

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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.

4. Engage motor lever.

Checking Expansion Tank and System Pressure

Mixing Valve Movement and Leak Check

Check proper expansion tank and system pressures

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.

CAUTIONDamage on boiler or other system components may result if these recommendations are not followed.

IMPORTANTThe diaphragm expansion tank must be able to hold the heating water expansion volume inside the boiler, and must be properly sized for the system.

CAUTIONCarry 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.

IMPORTANTCarry out this test on a cold system.

See expansion tank manufacturer’s instructions.

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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service ServiceChecking Air Intake in the Installation Room (visual check)

Check filter and air intake during room-air-dependent operation.

The system manufacturer must hand over the operating instructions to the system operator and instruct him in its operation.

1. Complete customer information file and separate: Hand over segment for system operator to system operator. Retain segment for heating contractor in files.

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.

This includes all accessories that have been installed as components, such as remote controls. The system manufacturer must also provide instruction regarding maintenance work.

Check the air intake outside the installation room as well during room-air-dependent operation.

Instructing the Operator of the System

Operating and Service Documents

Replacing the Supply Air Filter (for room air dependant operation)

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Boiler Water Temperature ControlFunction Description

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 functionEnable the emissions test function on all control units.

The following functions are activated:

H Burner start

H Starting all pumpsNote: Only the heating circuit pump is switched ON in the case of boiler section 2/boiler section 3 control (this can be achieved through the relay test function of the lead boiler 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 descriptionThe supply temperature is regulated by starting or stopping the burners or by starting/stopping individual burner stages.

H Standalone control (see page 124)

H Sequential control (see page 124)

H Subject to system version, a difference is made between the condensing strategy (see page 125)

and 2 conventional boiler strategies (see pages 126 and 127).

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description Cascade Control Unit (continued)

Set supply temperatureThe 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 controlNote: 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 The cascade control specifies the set boiler water temperature for all currently active boilers. Every boiler control unit regulates to the specified set value.

The following control strategies are available:

H Condensing strategy (see page 125)

H Conventional boiler strategy 1 (see pages 126)

H Conventional boiler strategy 2 (see pages 127)

H Without and with supply temperature sensor

(see the following table).

H The control strategy is set automatically to conventional boiler strategy 2, coding “3c:2” in the “Cascade” group (see page 157).

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. If the boiler section 1 (condensing boiler) does not achieve the specified set value, it will only act to control the return temperature of the conventional boiler downstream. The conventional boiler is started late and is also shut down late.

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 control strategy is set automatically to conventional boiler strategy 2, coding “3c:2” in the “Cascade”group (see page 157).

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).

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Cascade Control Unit (continued)


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.

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%)


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.

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

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description Cascade Control Unit (continued)

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 wereramped 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.

Conventional boiler strategies

Examples Two-boiler system with modulating burners:



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Conventional boiler strategy 1 (coding “3c:1” in the “Cascade” group)

Starting Shutdown

Cascade Control Unit (continued)


Starting Shutdown

Conventional boiler strategy 2 (coding “3c:2” in the “Cascade” group)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function DescriptionHeating Circuit Control

Only for single boiler and cascade control units

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).

FunctionsThe 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 programThe 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.

Outdoor temperatureA heating curve must be set for matching the control unit to the building and the heating system.The heating curve characteristics determine the set boilerwater temperature subject to outdoor temperature. The control unit uses an average outdoor temperature.This comprises the actual and the adjusted outdoor temperature.

Room temperatureIn 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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description Heating Circuit Control (continued)

DHW temperaturePriority 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

Heating circuit pump logic – Economy circuitsThe 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.

H The actual room temperature exceeds the value set in coding “b5” in the “Heating circuit ...” group.

System dynamicsThe mixing valve control characteristics can be influenced at coding “c4” in the “Heating circuit...” group.

Central controlCoding “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 protectionThe 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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function DescriptionHeating Circuit Control (continued)

Supply temperature control single boiler control unitDifferential 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 temperatureof 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.

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.

Supply temperature control cascade control unitDifferential 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 theheating 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.

LegendA Max. boiler water temperatureB Slope = 1.8 for heating circuit without mixing valveC Slope = 1.2 for heating circuit with mixing valveD Boiler water temperature [with a differential temperature = 15°F (8 K)]E Lower boiler water temperature, defaulted by the boiler coding card

LegendA Maximum supply temperature limit (coding “37” in the “Cascade” group)B Slope = 1.8 for heating circuit without mixing valveC Slope = 1.2 for heating circuit with mixing valveD Common supply temperature [at a differential temperature = 15°F (8 K)]E Lower common supply temperature

Sup

ply

tem

pera

ture

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description Heating Circuit Control (continued)

Raising the reduced room temperatureDuring 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 timeDuring 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 automaticallyraised.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 sequenceMixing valve circuitThe 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.

LegendA Heating curve for operation with standard room temperatureB Heating curve for operation with reduced room temperature

LegendA Start of operation with standard room temperatureB Set boiler water or supply temperature in accordance with the selected heating curveC 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

Example using the settings in the factory set condition

Example using the settings in the factory set condition

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description

DHW Tank Temperature Control

Brief description

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).

FunctionsTime programAn 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.

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 protectionThe 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 temperatureThe set DHW temperature can be adjusted between 50°F and 140°F (10°C 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 pumpThis delivers hot water to the draw-off points at adjustable times. Four time phases can be selected at the control unit for every day.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function Description DHW Tank Temperature Control (continued)

Auxiliary circuitsDHW 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 systemThe 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 unitA third set DHW temperature can be assigned at coding “67” in the “DHW” group.The DHW tank is only reheated by the boiler if thetemperature falls below this value.

Controlled sequence single boiler controlCoding “55:0” in the “DHW” group; tank heatingThe 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”).

H Without pump delay off (coding “62:0”).

Adaptive tank heatingCoding “55:1” in the “DHW” group; 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.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Function DescriptionDHW Tank Temperature Control (continued)

Tank temperature control with 2 tank temperature sensorsCoding “55:2” in the “DHW” group;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”)


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”)

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.


H Tank temperature sensor 1: Actual value ≥ set valueand... 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”.

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Vitocrossal 300 CA3 Series 2.5 to 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).

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.

LegendA CodingB Number of codingC Value of codingD Coding description

Display for coding levels

Resetting Coding to their Factory Set Condition

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”

6. Select group.7. Select coding.8. “Edit”9. for the required value in line with the following

tables.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Coding Level 1

“General” Group

Coding

Coding in the factory set condition Possible changeSystem design00:1 System version 1:

One heating circuit without mixing valve A1 (heating circuit 1), without DHW heating

00:2to00:10

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 heating5 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 changeServomotor runtime40:125 Actuator runtime at plug gSA1 125 sec.

Do not adjust!40:5to40:199

Adjustable from 5 to 199 sec.

LON participant no.77:1 LON Participant number

Boiler section 1 set to 1, boiler section 2 set to 2 boiler section 3 set to 3.

IMPORTANTIf coding is to be set to the factory set condition, the participant number must be reset.

77:1to77:99

Adjustable from 1 to 99:1 to 8 = Boiler section 10 - 96 = Vitotronic 200-H97 = Vitogate 30098 = Vitogate99 = Vitocom

“Detached house/apartment building”7f:1 Detached house 7F:0 Apartment building

Separate adjustment of holiday program and time program for DHW heating possible.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Coding Level 1 “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.

“Summer time starts: Month”

82:3 March 82:1to82:12

January to December

“Summer time starts: Week of the selected month”

83:2 Week 2 of the selected month. 83:1to83:5

Week 1 to week 5 of the selected month.

83:6 Last week - 1 week

83:7 Last week - 2 weeks



83:10to83:14

Special function

“Summer time starts: Day of the selected week”

84:7 Last Sunday of the selected month. 84:1to84:7

Monday to Sunday.

“Wintertime starts: Month”

85:11 November 85:1to85:12

January to December

“Wintertime starts: Week of the selected month”

86:1 Week 1 of the selected month. 86:1to86:5


“Wintertime starts: Day of the selected week”

87:7 Last Sunday of the selected month. 87:1to87:7

Monday to Sunday

“Operation enabled/blocked”

8f:0 Do not adjust! -- --

“Set supply temperature for external demand”

9b:70 Set to 158°F (70°C) 9b:0to9b:127

Adjustable from 32°F to 261°F (0°C to 127°C) (limited by boiler specific coding).

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“Combustion Controller” Group

Coding


“Max operational output”

02:100 100% of rated heating output. 02:0to02:100

Adjustable from 0 to 100%(0% represents burner minimum firing rate).

“Gas type”

03:0 Natural gas 03:1 Liquid Propane Gas

“Altitude”

04:0 LA: ≤ 5000 ft. (1500 m) above sea level 04:1 HA: > 5000 ft. (1500 m) above sea level

“Max boiler temperature”

06:95 Set to 203°F (95°C). 06:5to06:127

Adjustable from 41°F to 261°F (5°C to 127°C).

IMPORTANTSupply temperature limit switch common supply, (set to 210°F 99°C) [tolerance -11°F (-6K)].

“Integral threshold value of controller”

08:30 Set to 30 Kmin. 08:1to08:255

Adjustable from 1 to 255 K min

“Runtime optimization”

09:1 Integral method 09:0 Minimum pause


“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!

“Consecutive boiler number in multi boiler systems”

07:1 Consecutive boiler section number in multi boiler systems.

07:2to07:8

Adjustable from 1 to 87:1 Lead boiler section7:2-8 Lag boiler sections

“Flue gas temperature sensor”

1f:0 Do not adjust! -- --

“Service interval”

21:0 No service interval (hours run) selected. 21:1to21:100

The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h; 1 step 100 h.

“Interval for service”

23:0 No interval for service. 23:1to23:24

Adjustable from 1 to 24 months.

“Boiler” Group

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Coding


“Number of boilers connected to the cascade”

35:2 to 3

Boiler sectionsFactory set conditions:CA3 2.5/3.0/3.5/4.0: 2CA3 5.0/6.0: 3

35:1to35:8

1 to 8 boiler sections connected to lead control

“Minimum system supply temperature limit”

36:0 Electronic minimum system supply temperature limit set to 32°F (0°C).

36:1to36:127

Adjustable from 32°C to 261°C (0°C to 127°C) (only when operating with standard room temperature).

“Maximum system supply temperature limit”

37:80 Electronic maximum system supply temperature limit set to 176°F (80°C).

37:20to37:127


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 boiler sequence changeover Do not adjust!

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.

38:2to38:200

Boiler section 1 changeover after 200 to 20,000 hours run1 step 100 hours run.

“Permanent boiler section 1”

39:0 No permanent lead boiler section.Do not adjust!

39:1to39:3

Permanent lead boiler section is 1, 2, 3, 4, 5, 6, 7 or 8.

“Permanent last boiler”

3a:0 No permanent last boiler section.Do not adjust!

3a:1to3a:3

Permanent last boiler section is 1, 2, 3, 4, 5, 6, 7 or 8.


”Service” display”

24:0 No “Service” display 24:1 “Service” is displayed (the address is automatically set and must be manuallyreset after a service has been carried out).

“Cascade” Group

“Boiler” Group (continued)

140

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“Cascade” Group (continued)

“ECO threshold boiler 1”

41:31 No ECO threshold boiler 1.Do not adjust!

41:−30to41:+30

Adjustable from -22°F to 86°F (−30°C to +30°C).



42:−30to42:+30




43:−30to43:+30




44:−30to44:+30



“Type of control”

3b:1 Standalone parallel boiler circuit:With supply temperature sensor (see page 124).

3b:0 Standalone parallel boiler circuit:Without supply temperature sensor (see page 124).

3b:2 Standalone serial boiler circuit:Without supply temperature sensor (see page 124).

3b:3 Standalone serial boiler circuit:With supply temperature sensor (see page 124).

3b:4 Sequential control method with supply temperature sensor (see page 124).

“Control strategy”

3c:0 Condensing strategy (see page 125). 3c:1 Conventional boiler strategy 1 (see page 126).

3c:2 Conventional boiler strategy 2 (see page 127).

“Output statement”

3d:1 Output statement for condensing strategy and conventional boiler strategy 1.

3d:0 No output statement

Note: Control only in accordance with conventional boiler strategy 2.

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“Stop differential”

47:15 Set to 27°F (15 K). 47:2to47:30

Adjustable from 4°F to 54°F (2 K to 30 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.



65:−30to65:+30



6F:31 No ECO threshold boiler 6.Do not adjust!

6F:−30to6F:+30




74:−30to74:+30



7d:31 No ECO threshold boiler 8.Do not adjust!

7d:−30to7d:+30



“DHW” Group

Coding

Coding in the factory set condition Possible change“Storage tank heating, hysteresis”

55:0 Tank heating hysteresis ± 5°F (2.5 K). 55:1 Adaptive storage tank heating enabled (see page 133).

55:2 Storage tank temperature control with 2 temperature sensors (see page 134).

55:3 Storage tank temperature control, storage tank loading system.Do not adjust!

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Coding in the factory set condition Possible change“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).

67:0to67:95

Adjustable from 32°F to 203°F (0°C to 95°C)(limited by boiler-specific coding).

“DHW recirculation pump”73:0 ON according to time program 73:1

to73:6

“ON” from once per hour for 5 min up to 6 times per hour for 5 min during the time program.

73:7 Permanently ON

“DHW” Group (continued)

Coding

Coding in the factory set condition Possible change“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. “Maximum storage tank temperature”08:60 DHW setpoint temperature (maximum tank

temperature) 140°F (60°C).08:10to08:90


“Stagnation time reduction”0a:5 Temperature differential for stagnation time

reduction (reduction in the speed of the solar circuit pump to protect system components and heat transfer medium) 11°F (5 K).

0a:0 Stagnation time reduction disabled.

0a:1to0a:40

Temperature differential adjustable from 2°F to 72°F (1 K to 40 K).

“Solar circuit flow rate”0f:70 Solar circuit flow rate at maximum pump

speed 1.8 USG/min (7 L/min).0f:1to0f:255

Adjustable from 0.02 USG/min to 6.7 USG/min (0.1 L/min to 25.5 L/min),1 step 0.02 USG/min (0.1 L/min).

“Solar” Group

Note: The “Solar” group is only displayed if a solar control module, type SM1, is connected.

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“Extended control function”20:0 No extended control function enabled. 20:1 Additional function for DHW heating.

20:2 Differential temperature control 2.20:3 Differential temperature control 2 and auxiliary

function.20:4 Differential temperature control 2 for central

heating backup.20:5 Thermostat function20:6 Thermostat function and auxiliary function.20:7 Solar heating via external heat exchanger

without additional temperature sensor.20:8 Solar heating via external heat exchanger with

additional temperature sensor.20:9 Solar heating of two DHW storage tanks.

“Solar” Group (continued)

“Heating Circuit ...” Group Coding

Coding in the factory set condition Possible change“Storage tank priority”a2:2 Tank priority control for heating circuit

pump and mixing valve.a2:0 Without storage tank priority applicable

to heating circuit pump and mixing valve.a2:1 Storage tank priority only applicable to

mixing valve.a2:3toa2:15

Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat.

“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 2°F (1 K) higher than the set room temperature (RTset) OT > RTset +2°F (1 K).

a5:0 Without heating circuit pump logic function.

a5:1toa5:15

With heating circuit pump logic function: Heating circuit pump OFF, see the following table.

Coding address a5:...

With heating circuit pump logic function: Heating circ pump OFF

1 OT > RTset +9°F (+ 5 K)2 OT > RTset +7°F (+ 4 K)3 OT > RTset +5°F (+ 3 K)4 OT > RTset +4°F (+ 2 K)5 OT > RTset +2°F (+ 1 K)6 OT > RTset7to15

OT > RTset –2°F (– 1 K)

OT > RTset –16°F (– 9 K)

144

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“Heating Circuit ...” Group (continued)

Coding in the factory set condition Possible change“Extended economy mode”a6:36 Extended economy mode disabled. a6:5

toa6:35

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°F to 95°F (5°C 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.

“Mixing valve economy function”a7:0 Only for heating circuits with mixing

valve:Without mixing valve economy function.

a7:1 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.

H If there is a risk of frost“Pump idle time”a9:0 Without pump idle time. a9:7 With pump idle time (heating circuit

pump turned off).Function description page 131

Note: The maximum idle time is 10 h.

a9:1toa9:15

Pump idle time adjustable from 1 to 15.1: Short idle time15: Long idle time

“Room temperature hook-up”b0:0 With remote control:*1

Heating mode/reduced mode: Weather-compensated

b0:1 Heating mode: Weather-compensated Reduced mode: with room temperature hook-up

b0:2 Heating mode: with room temperature hook-upReduced mode: Weather-compensated

b0:3 Heating mode/reduced mode: with room temperature hook-up.

“Room temperature-dependent heating circuit pump logic function”b5:0 With remote control:

No room temperature-dependent heating circuit pump logic function.

b5:1tob5:8

For heating circuit pump logic function, see the following table:

*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.

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Coding address b5:...

With heating circuit pump logic function: Heating circ pump OFF Heating circuit pump on

1 RTactual > RTset +9°F (+ 5 K) RTactual < RTset +7°F (+ 4 K)2 RTactual > RTset +7°F (+ 4 K) RTactual < RTset +5°F (+ 3 K)3 RTactual > RTset +5°F (+ 3 K) RTactual < RTset +4°F (+ 2 K)4 RTactual > RTset +4°F (+ 2 K) RTactual < RTset +2°F (+ 1 K)5 RTactual > RTset +2°F (+ 1 K) RTactual < RTset6 RTactual > RTset RTactual < RTset –2°F (– 1 K)7 RTactual > RTset –2°F (– 1 K) RTactual < RTset –4°F (– 2 K)8 RTactual > RTset –4°F (– 2 K) RTactual < RTset –5°F (– 3 K)

Coding in the factory set condition Possible change“Minimum supply temperature limit”c5:20 Electronic supply temperature minimum

limit 68°F (20°C) (only for operation with standard room temperature).

c5:1toc5:127


“Maximum supply temperature limit”c6:75 Electronic maximum supply temperature

limit set to 167°F (75°C).c6:10toc6:127


“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).

d5:1 Changeover to “Constant operation with standard room temperature”.

“EA1 extension: Operating program changeover”

d8:0 No operating program changeover. d8:1 Operating program changeover via input DE1.

d8:2 Operating program changeover via input DE2.


“Slab curing”

f1:0 Slab curing function not active.Do not adjust!

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“Time limit for comfort mode”

f2:8 Time limit for comfort mode or external operating program changeover via push button: 8 h.

Note: Observe setting of coding “5d”, “5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” group.

f2:0 No time limit

f2:1tof2:12

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 131.Observe coding “a3”.

f8:+10tof8:–60

Adjustable from 50°F to -76°F (+10°C 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 131.

f9:+10tof9:–60


“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 temperature when changing from operationwith reduced room temperature to operation with standard room temperature by 20%. See example on page 189.

fa:0tofa:50

Adjustable from 0 to 50%.

“Duration for raising the set boiler water or supply temperature”

fb:60 Duration for raising the set supply temperature (see coding “fa”) 60 min.See example on page 131.

fb:0tofb:300

Adjustable from 0 to 300 min.


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“General” Group

Coding

Coding in the factory set condition Possible changeSystem design00:1 System version 1:

One heating circuit without mixing valve A1 (heating circuit 1), without DHW heating.

00:2to00:10

For system schemes, see the following table:

Value address00: ...

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.

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

brief operation: 5 min.12:1to12:60


“With EA1 extension: Temperature demand”1e: No factory setting

No factory setting. 1E:0 Analog input 0-10 V: Temperature demand from 32°F to 212°F (0°C to 100°C):1 V 32°F (0°C)10 212°F (100°C)

1E:1 Adjustable from 86°F to 248°F (30°C to 120°C):1V 86°F (30°C)10V 248°F (120°C)

2f:0 Do not adjust!“AM1 extension”32:0 Without AM1 extension 32:1 With AM1 extension“Function output A2 at AM1 extension”33:1 Heating circuit pump, heating circuit

without mixing valve A1 (heating circuit 1).

33:0 DHW recirculation pump33:2 DHW loading pump33:3 Circulation pump neutralizing system

or flue gas/water-heat exchanger.

Coding Level 2

148

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“General” Group (continued)

Coding in the factory set condition Possible change“Function output A1 at AM1 extension”34:0 DHW recirculation pump. 34:1 Heating circuit pump without mixing valve A1

(Heating circuit 1).34:2 Tank loading pump34:3 Circulation pump neutralizing system or flue

gas/water-heat exchanger.“Servomotor runtime”

40:125 Servomotor runtime at plug gSA1 125 secDo not adjust!

40:5to40:199

Adjustable from 5 sec. to 199 sec.

“Sensor 17A”4a:0 Do not adjust! -- --“Sensor 17B”

4b:0 No sensor aJB installed. 4b:1 Sensor aJB installed (e.g. temperature sensor T2); automatic recognition.

“Connection at plug 20A1”4c:0 Connection on plug sÖA1:

Heating circuit pump4c:1 Primary pump, tank loading system.

4c:2 Thermal control switch contact .

“Connection at plug 29”4d:1 Connection at plug sL: Shunt pump. 4d:0 System pump

4d:2 Boiler pump4d:3 Boiler pump with isolation valve function.

“Connection at plug 52A1”4e:0 Motor isolation valve. 4e:1 Motor for 3-way mixing valve for return

temperature control.4e:1to4e:3

Do not adjust!

“Delay off time, shunt or system pump”4f:5 Delay off time system pump 5 min. 4f:0 No pump delay off.

4f:1to4f:60


“Supply temperature sensor for hydraulic low loss header”52:0 Do not adjust!

“Solar thermal system”54:0 Without solar thermal system. 54:1

to54:3

Do not adjust!

54:4 With solar control module, type SM1, with auxiliary function, e.g. central heating backup; automatic recognition.

“EA1 extension”5b:0 Without EA1 extension. 5b:1 With EA1 extension; automatic recognition.

Coding Level 2

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“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).

“Function input DE1 at EA1 extension”

5d:0 No function 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:0 No function 5e:1 Operating program changeover

5e:2 External demand with minimum set supply temperature Set value adjustment at coding“9b” in the “General” group.

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.

150

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5f:0 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

neutralizing system: None6c:1to6c:255

Adjustable from 1 to 255 sec

“Shutdown delay neutralization system output 2 AM1”6d:0 Delay off time circulation pump

neutralizing system: None6d:1to6d:255

Adjustable from 1 to 255 sec

“Display correction for outdoor temperature”6e:50 No display correction for outdoor

temperature.6e:0to6e:49

Display correction –9°F (–5 K)toDisplay correction –0.2°F (–0.1 K)

6e:51to6e:99

Display correction +0.2°F (+0.1 K)toDisplay correction +9°F (+4.9 K)

“LON communication module”76:1 With LON communication module;

automatic recognition. 76:0 Without LON communication module.

“LON participant number”77:1 LON participant number

Boiler section 1 set to 1, boiler sec-tion 2 set to 2 boiler section 3 set to 3.

IMPORTANTIf coding is to be set to the factory set condition, the participant number must be reset.

77:2to77:99

Adjustable from 1 to 99:1 to 8 = Boiler section10 - 96 = Vitotronic 200-H97 = Vitogate 30098 = Vitogate99 = Vitocom

“LON communication”78:1 LON communication enabled 78:0 LON communication disabled

Coding Level 2


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Coding in the factory set condition Possible change“With LON communication module”79:1 Control unit is fault manager. 79:0 Control unit is not fault manager

IMPORTANTMust be set for boiler section 2/boiler section 3, see page 87.

“Central control of heating circuits”7a:0 Without central control of heating

circuits.7a:1 With central control Heating circuit without

mixing valve A1 (heating circuit 1).7a:2 Heating circuit with mixing valve M2

(heating circuit 2).7a:3 Heating circuit with mixing valve M3

(heating circuit 3).“LON communication module: Time”7b:1 Control unit transmits the time. 7b:0 No time transmission

IMPORTANTMust be set for boiler section 2/boiler section 3, see page 87.

“Detached house/apartment building”7f:1 Detached house 7F:0 Apartment building

Separate adjustment of holiday program and time program for DHW heating possible.

“Fault message”80:6 A fault message is issued if a fault

occurs for at least 30 sec.80:0 Immediate fault message.80:2to80:199

Adjustable from10 to 995 sec,1 step 5 sec.

“Automatic summer/wintertime changeover”81:1 Automatic summer/wintertime

changeover.81:0 Manual summer/wintertime changeover81:2 Do not adjust!81:3 With LON communication module:

The control unit receives the time.“Summer time starts: Month”82:3 March 82:1

to82:12

January to December

152

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Coding in the factory set condition Possible change“Summer time starts: Week of the selected month”83:2 Week 2 of the selected month. 83:1

to83:5

Week 1 to week 5 of theselected month.

83:6 Last week – 1 week83:7 Last week – 2 week83:8 Last week – 3 week83:9 Last week – 4 week83:10to83:14

Special function

“Summer time starts: Day of the selected week”84:7 Last Sunday of the selected month. 84:1

to84:7

Monday to Sunday

“Wintertime starts: Month”85:11 November 85:1

to85:12

January to December

“Wintertime starts: Week of the selected month”86:1 Week 1 of the selected month. 86:1

to86:5


“Wintertime starts: Day of the selected week”87:7 Last Sunday of the selected month. 87:1

to87:7

Monday to Sunday

“Temperature displayed”88:0 Temperature unit °C (Celsius). 88:1 Temperature unit °F (Fahrenheit)“Test display conditions” 8a:175 Do not adjust! -- --“Identification KM bus combustion controller”8b:1 ID exists 8b:0 ID does not exist“Operation enabled/blocked”8f:0 Do not adjust! -- --“Time constant for calculating adjusted outdoor temperature”90:36 Time constant 6 h. 90:1

to90:199

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.

Coding Level 2


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“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

“Communication interface”

95:0 Without Vitocom 100 communication interface.

95:1 With Vitocom 100 communicationinterface; automatic recognition.

“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.

96:0 Without PCB extension for heating circuits 2 and 3.

“With LON communication module: Outdoor temperature”

97:2 The control unit sends the outdoor temperature to the Vitotronic 200-H.

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.

“Viessmann system number”

98:1 Viessmann system number in conjunction with monitoring of several systems within one LON system with Vitocom 300.

98:1to98:5

Adjustable from 1 to 5

154

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Coding Level 2


“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

“Connection at terminals 1 and 2 in plug 143 “

9a:0 Connection disabled. 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

“Set supply temperature for external demand”

9b:70 Set to 158°F (70°C). 9b:0to9b:127


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“With LON communication module: Monitoring LON participants”

9c:20 Monitoring LON participantsIf 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:5to9c:60

Time adjustable from 5 to 60 min.

“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).

9f:0to9f:40

Adjustable from 0 to 40 K

Coding Level 2


Coding


“Max operational output”

02:100 100% of rated heating output. 02:0to02:100

Adjustable from 0 to 100%(0% represents burner minimum firing rate).

“Gas type”

03:0 Natural gas 03:1 Liquid Propane Gas

“Altitude”

04:0 LA: ≤ 5000 ft. (1500 m) 04:1 HA: > 5000 ft. (1500 m)

“Max boiler temperature”

06:95 Set to 203°F (95°C) 06:5to06:127

Adjustable from 41 to 261°F (5 to 127°C)

IMPORTANTSupply temperature limit switch common supply, set to 210°F (99°C) [tolerance -11°F (-6K)].

“Integral threshold value of controller”

08:30 Set to 30 K min 08:1to08:255

Adjustable from 1 to 255 K min.

“Runtime optimization”

09:1 Integral method 09:0 Minimum pause.

“Flue gas damper”

0a:0 Without 0a:1 Do not adjust!

“Combustion Controller” Group

156

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“Boiler” GroupCoding Level 2

Coding


“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!

“Consecutive boiler number in multi boiler systems”

07:1 Consecutive boiler section number in multi boiler systems.

07:2to07:8

Adjustable from 1 to 87:1 Lead boiler section7:2-8 Lag boiler sections

“Therm Control”

Od:0 Without Od:1 Do not adjust!

Od:2 Do not adjust!

“Flue gas temperature sensor”

1f:0 Do not adjust!

“Service interval”

21:0 No service interval (hours run) selected. 21:1to21:100

The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h;1 step 100 h

“Interval for service”

23:0 No interval for service. 23:1to23:24

Interval adjustable from 1 to 24 months.

”Service” display”

24:0 No “Service” display. 24:1 “Service” display.The address is automatically set and must be manually reset after a service has been carried out.

“Maximum preheating time of isolation valve”

2b:5 Preheating time 5 min. 2b:1to2b:60

Maximum preheating time of isolation valve, adjustable from 1 to 60 min.

“Maximum shutdown delay of isolation valve”

2c:5 Shutdown delay 5 min. 2c:1to2c:60

Maximum shutdown delay of isolation valve, adjustable from 1 to 60 min.

“Cascade” Group

Coding


“Number of boilers connected to the cascade”

35:2 or 3 Boiler sectionsFactory set condition:CA3 2.5/3.0/3.5/4.0: 2CA3 5.0/5.0: 3

35:1to35:8

1 to 8 sections connected to the lead control

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“Minimum system supply temperature limit”

36:0 Set to 32°F (0°C). 36:1to36:127

Adjustable from 32°F to 261°F (0 to 127°C) (only when operating with standard room temperature).

“Maximum system supply temperature limit”

37:80 Set to 176°F (80°C). 37:20to37:127

Adjustable from 68°F to 261°F (20 to 127°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 boiler sequence changeover Do not adjust!

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.

38:2to38:200

Boiler section 1 changeover after 200 to 20,000 hours run1 step 100 hours run.

“Permanent boiler section 1”

39:0 No permanent lead boiler section.Do not adjust!

39:1to39:8

Permanent lead boiler section is 1, 2, 3, 4, 5, 6, 7 or 8.

“Permanent last boiler”

3a:0 No permanent last boiler section.Do not adjust!

3a:1to3a:8

Permanent last boiler section is 1, 2, 3, 4, 5, 6, 7 or 8.

“Type of control”

3b:1 Standalone parallel boiler circuit:With supply temperature sensor (see page 124).

3b:0 Standalone parallel boiler circuit:Without supply temperature sensor (see page 124).

3b:2 Standalone serial boiler circuit:Without supply temperature sensor (see page 124).

3b:3 Standalone serial boiler circuit:With supply temperature sensor(see page 124).

3b:4 Sequential control method with supply temperature sensor(see page 124).

“Control strategy”

3c:0 Condensing strategy (see page 125). 3c:1 Conventional boiler strategy 1 (see page 126).

3c:2 Conventional boiler strategy 2 (see page 127).

“Output statement”

3d:1 Output statement for condensingstrategy and conventional boiler strategy 1.

3d:0 No output statementControl only in accordance with conventional boiler strategy 2.


Coding Level 2

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Coding Level 2


“System pump”

3e:0 System pump will only run if there is a heat demand.

3e:1 System pump always runs; shutdown through “External blocking” signal.

“Tank priority control for system pump”

3f:0 Without tank priority control for system pump.

3f:1 With tank priority control for system pump.



41:−30to41:+30




42:−30to42:+30




43:−30to43:+30




44:−30to44:+30


“Stop differential”

47:15 Set to 15 K. 47:2to47:30

Adjustable from 4°F to 54°F (2 K to 30 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.



65:−30to65:+30

Adjustable from -22°F to +86°F (-30°C to +30°C).

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6f:31 No ECO threshold boiler 6.Do not adjust!

6f:−30to6f:+30




74:−30to74:+30



7d:31 No ECO threshold boiler 8.Do not adjust!

7d:−30to7d:+30



Coding Level 2

“DHW” Group

Coding


“Storage tank heating, hysteresis”

55:0 Tank heating, hysteresis ±5°F (±2.5 K). 55:1 Adaptive storage tank heating enabled (see page 133).

55:2 Storage tank temperature control with 2 tank temperature sensors (see page 134).

55:3 Storage tank temperature control, storage tank loading system.Do not adjust!

“DHW temperature target”

56:0 Set DHW temperature adjustable from 50 to 140°F (10 to 60°C).

56:1 Adjustable from 50°F to above 140°F (10°C to above 60°C).

Note: Observe the max. permissible DHW temperature.

“Additional function for DHW heating”

58:0 Without additional function for DHW heating.

58:10to58:60

Input of a second set DHW temperature; adjustable from 50°F to 203°F (10°C to 95°C).(observe coding “56”).

“Tank heating: Set start point”

59:0 Set start point –5°F (–2.5 K)Set stop point +5°F (+2.5 K)

59:1to59:10

Adjustable from 1 K to 10 K below set value.

“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.”).

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.”).

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Coding Level 2

Coding in the factory set condition Possible change“Boiler temperature during DHW heating”

60:20 During DHW heating, the boiler water temperature is up to 36°F (20 K) higher than the set DHW temperature.

60:10to60:50

The differential between the common supply temperature and the set DHW temperature is adjustable from 11°F to 90°F (10 K to 50 K).

“DHW pump”

61:1 DHW pump starts immediately. 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.

62:0 No DHW pump delay off62:1to62:15

Delay off time adjustable from 1 to 15 min.

“In comfort mode and after external changeover to constant operation with the standard room temperature”

64:2 Enable constant DHW heating and DHW pump “ON”.

64:0 No DHW heating; DHW pump “OFF”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

unit and all installed Vitotrol 300A remote controls.

66:0 At the programming unit of the control unit.

66:1 At the programming unit of the control 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

(40°C). Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient).

67:0 No set value 367:10to67:95

DHW setpoint temperature adjustable from 50°F to 203°F (10°C to 95°C) (limited by boiler-specific coding). Observe setting of coding “56”.

“With 2 tank temperature sensors: Tank heating stop point”68:8 With 2 tank temperature sensors (coding

“55:2”): Tank heating stop point at set value x 0.8.

68:2to68:10

Factor adjustable from 0.2 to 11 step 0.1

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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

“55:2”): Tank heating start point at set value x 0.7.

69:1to69:9

Factor adjustable from 0.1 to 0.91 step 0.1.

“Runtime, actuator, mixing valve, heat exchanger set, Vitotrans 222”6A:75 Runtime, servomotor, mixing valve, heat

exchanger set, Vitotrans 222, (80 and 120 kW): 75 sec.

6A:10to6A:255

For heat exchanger set Vitotrans 222 (240 kW): set 113 sec. Runtime adjustable from 10 to 255 sec.

“DHW recirculation pump”70:0 DHW recirculation pump “ON” according

to time program when DHW heating is enabled.

70:1 DHW recirculation pump “ON” according to time program.


71:1 “OFF” during DHW heating to set value 1.71:2 “ON” during DHW heating to set value 1.


72:1 “OFF” during DHW heating to set value 2.72:2 “ON” during DHW heating to set value 2.


73:1to73:6

“ON” from once per hour for 5 min up to 6 times per hour for 5 min during thetime program.

73:7 Constantly “ON”


75:1 DHW recirculation pump “OFF” during economy mode.


Coding Level 2

“Solar” Group


“Differential between the actual DHW temperature and the start point for the solar circuit pump”

00:8 Start temperature differential for solar circuit pump 14°F (8 K)

00:2to00:30


“Differential between the actual DHW temperature and the stop point of the solar circuit pump”

01:4 Stop temperature differential for solar circuit pump 7°F (4 K)

01:1to01:29


“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 controlledwith PWM control.

Only in conjunction with solar control module, type SM1.

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“Temperature differential between the collector temperature and actual DHW temperature”

03:10 Temperature differential for the start of speed control 18°F (10 K).

03:5to03:20


“Controller amplification of the speed control”

04:4 Controller amplification of the speed control 4%/K.

04:1to04:10

Adjustable from 1 to 10%/K.

“Minimum speed of the solar circuit pump”

05:10 Minimum speed of the solar circuit pump 10% of the maximum speed.

05:2to05:100


“Maximum speed of the solar circuit pump”

06:75 Maximum speed of the solar circuit pump 75% of maximum possible speed.

06:1to06:100


“Interval function of the solar circuit pump”

07:0 Interval function of the solar circuit pump switched off.

07:1 Interval function of the solar circuit pump switched on. To capture the collector temperature more accurately, the solar circuitpump starts for short cycles.

“Maximum storage tank temperature”

08:60 DHW setpoint temperature (maximum tank temperature) 140°F (60°C).

08:10to08:90


“Maximum collector temperature”

09:130 Maximum collector temperature(to protect system components) 266°F (130°C).

09:20to09:200


“Stagnation time reduction”

0a:5 Temperature differential for reducing thestagnation time (reduction in solar circuitpump speed to protect system components and heat transfer medium) 11°F (5 K).

0a:0 Stagnation time reduction disabled.0a:1to0a:40


“Frost protection function for solar circuit”

0b:0 Frost protection function for solar circuit switched off.

0b:1 Frost protection function for solar circuit switched on (not required with Viessmann heat transfer medium).

“Delta T monitoring”

0c:1 Delta T monitoring switched on. No flow rate captured in the solar circuit, or flowrate too low.

0c:0 Delta T monitoring switched off.

“Minimum collector temperature”

12:20 Minimum collector temperature(minimum solar circuit pump start temperature) 68°F (20°C).

12:0 No minimum limit.12:1to12:90



Coding Level 2

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Coding Level 2

Coding in the factory set condition Possible change“Night circulation monitoring”

0d:1 Night circulation monitoring switched on.Unintentional flow in the solar circuit is captured (e.g. at night).

0d:0 Night circulation monitoring switched off.

“Calculation of solar yield”

0e:1 Heat statement in conjunction with Viessmann heat transfer medium

0e:2 Do not adjust!0e:0 No heat statement.

“Solar circuit flow rate”

0F:70 Solar circuit flow rate at maximum pump speed 1.8 USG/min (7 L/min)

0f:1to0f:255

Flow rate adjustable from0.02 USG/min to 6.7 USG/min (0.1 L/min to 25.5 L/min)1 step 0.02 USG/min (0.1 L/min).

“Target temperature control”

10:0 Target temperature control OFF (see coding address “11”)

10:1 Target temperature control switched on.

“Set solar DHW temperature”

11:50 Set solar DHW temperature 122°F (50°C)

H Target temperature control switched on (code “10:1”):

Temperature at which the water in the DHW tank heated by solar energy is to be stratified.

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.

11:10to11:90


“Minimum collector temperature”

12:20 Minimum collector temperature(minimum solar circuit pump start temperature) 68°F (20°C).

12:0 No minimum limit12:1to12:90


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Coding Level 2

Coding in the factory set condition Possible change“Extended control function”20:0 No extended control function enabled. 20:1 Additional function for DHW heating.

20:2 Differential temperature control 2.20:3 Differential temperature control 2 and

auxiliary function.20:4 Differential temperature control 2 for

central heating backup.20:5 Thermostat function20:6 Thermostat function and auxiliary

function.20:7 Solar heating via external heat exchanger

without additional temperature sensor.20:8 Solar heating via external heat exchanger

with additional temperature sensor.20:9 Solar heating of two DHW storage tanks

[Solar heating of two DHW tanks].“Start temperature differential for central heating backup”22:8 Start temperature differential with central

heating backup 14°F (8 K) (code “20:4” must be set).

22:2to22:30

Start temperature differentialadjustable from 4°F to 54°F (2 K to 30 K).

“Stop temperature differential for central heating backup”23:4 Stop temperature differential with central

heating backup 7°F (4 K) (code “20:4” must be set).

23:2to23:30

Stop temperature differentialadjustable from 2°F to 52°F (1 to 29 K).

“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).

24:0to24:100


“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).

25:0to25:100


“Priority for DHW storage tank 1”26:1 Priority for DHW storage tank 1

with cyclical heating (code “20:9” must be set).

26:0 Priority for DHW storage tank 1 without cyclical heating.

26:2 Priority for DHW storage tank 2 without cyclical heating.

26:3 Priority for DHW storage tank 2 with cyclical heating.

26:4 Alternate heating without priority for one of the DHW storage tanks .

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Coding in the factory set condition Possible change“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.

27:5to27:60


“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.

28:1to28:60

Adjustable from 1 to 60 min..

Coding Level 2

“Heating Circuit ...” Group


Coding


“Remote control”

a0:0 Without remote control. a0:1 With Vitotrol 200, recognized automatically.

a0:2 Recognized automatically with Vitotrol 300.

“Blocking remote control”

a1:0 All possible settings at the remote control can be accessed.

a1:1 Only comfort mode can be set at the remote control.

“Storage tank priority”

a2:2 Tank priority for heating circuit pump and mixing valve.

a2:0 Without storage tank priority applicable to heating circuit pump and mixing valve

a2:1 Storage tank priority only applicable to mixing valve.

a2:3toa2:15

Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat.

“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.

a3:–9toa3:15

Heating circuit pump ON/OFF (see the following table).

CAUTIONIf 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.

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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)

2to15

34°F (+1°C)to57 F (+14°C)

27°F (+3°C)to61°F (+16°C)

Coding Level 2



“Frost protection”

a4:0 With frost protection a4:1 No frost protection; this setting is only possible if code a3:9has 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 2°F (1 K) higher than the set room temperature (RTset) OT > RTset 2°F (1 K).

a5:0 Without heating circuit pump logic function.

a5:1toa5:15

With heating circuit pump logic function: Heating circuit pump OFF, see the following table.

Coding addressa5:...

With heating circuit pump logic function: Heating circuit pump “OFF”

1 OT > RTset 9°F (+ 5 K)

2 OT > RTset 7°F (+ 4 K)

3 OT > RTset 5°F (+ 3 K)

4 OT > RTset 4°F (+ 2 K)

5 OT > RTset 2°F (+ 1 K)

6 OT > RTset

7to15

OT > RTset 2°F (– 1 K)

OT > RTset 16°F (– 9 K)

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“Extended economy mode”

a6:36 Extended economy mode disabled. a6:5toa6:35

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°F to 95°F (5°C 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.

“Mixing valve economy function”

a7:0 Only for heating circuits with mixing valve:Without mixing valve economy function.

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. a9:1toa9:15

Pump idle time adjustable from 1 to 15.1: Short idle time15: Long idle time

“Output reduction”

aa:2 With output reduction through temperature sensor aJA.

aa:0 Without output reduction.aa:1 No function.

“Room temperature hook-up”

b0:0 With remote control:*1Heating mode/reduced mode: Weather-compensated.

b0:1 Heating mode: Weather-compensatedReduced mode: with room temperature hook-up

b0:2 Heating mode: with room temperature hook-upReduced mode: Weather-compensated

b0:3 Heating mode/reduced mode: with room temperature hook-up.

“Room influence factor”

b2:8 With remote control and for the heating circuit, operation with room temperaturehook-up must be programmed:Room influence factor 8.

b2:0 Without room influence.

b2:1tob2:31

Adjustable from 1 to 31.

“Room temperature-dependent heating circuit pump logic function”

b5:0 With remote control:No room temperature-dependentheating circuit pump logic function.

b5:1tob5:8

For heating circuit pump logic function, see the following table on page 168.

*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.

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Coding addressb5:...

With heating circuit pump logic function:

Heating circuit pump “OFF” Heating circuit pump “ON”

1 RTactual > RTset +9°F (+5 K) RTactual < RTset +7°F (+4 K)




5 RTactual > RTset +2°F (+1 K) RTactual < RTset

6 RTactual > RTset RTactual < RTset –2°F (–1 K)

7 RTactual > RTset –2°F (–1 K) RTactual < RTset –4°F (–2 K)

8 RTactual > RTset –4°F (–2 K) RTactual < RTset –5°F (–3 K)


“Quick heat-up/quick setback”

b6:0 With remote control:Without quick heat-up/quick setback.

b6:1 With quick heat-up/quick setback.(see function description on page 128).

“Start optimization”

b7:0 With remote control and for the heating circuit, operation with room temperature.hook-up must be programmed:Without start optimization.

b7:1 With start optimization, max. heat-up time offset 2 h 30 min.

b7:2 With start optimization, max. heat-up time offset 15 h 50 min.

“Heat-up gradient start optimization”

b8:10 With remote control and for the heating circuit, operation with room temperaturehook-up must be programmed:Heat-up gradient start optimization 10 min/K.

b8:11tob8:255

Adjustable from 11 min/K to 255 min/K

“Learning start optimization”

b9:0 With remote control and for the heating circuit, operation with room temperaturehook-up must be programmed:Without learning start optimization.

b9:1 With learning start optimization

“Shutdown time optimization”

c0:0 With remote control:Without shutdown time optimization.

c0:1 With stop optimization, max. setback time offset 1 h.

c0:2 With stop optimization, max. setback time offset 2 h.

“Stop optimization of setback time offset”

c1:0 With remote control:Without shutdown time optimization.

c1:1toc1:12

With stop optimization of setback time offset adjustable from 10 min. to 120 min.1 step 10 min.

“Learning shut-down time optimization”

c2:0 With remote control:Without learning shutdown time optimization.

c2:1 With learning shut-down time optimization.

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Coding Level 2


“Mixing valve runtime”

c3:125 Only for heating circuits with mixing valve:Mixing valve runtime 125 sec.

c3:10toc3:255

Adjustable from 10 sec. to 255 sec.

“System dynamics mixing valve”

c4:1 System dynamics:Mixing valve control characteristics.

c4:0toc4:3

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.

“Minimum supply temperature limit”

c5:20 Electronic minimum supply temperature limit 68°F (20°C) (only when operating with standard room temperature).

c5:1toc5:127


“Maximum supply temperature limit”

c6:75 Electronic maximum supply temperature limit set to 167°F (75°C).

c6:10toc6:127


“Room influence limit”

c8:31 With remote control and for the heating circuit, operation with room temperaturehook-up must be programmed:No room influence limit

c8:1toc8:30


“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).

d5:1 Changeover to “Constant operation with standard room temperature”.

“EA1 extension: Operating program changeover”

d8:0 No operating program changeover. d8:1 Operating program changeover via input DE1.



“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.

e2:0toe2:49

Display correction –9°F (–5 K)toDisplay correction –0.2°F (–0.1 K)

e2:51toe2:99

Display correction +0.2°F (+0.1 K)toDisplay correction +9°F (+4.9 K)

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Coding Level 2


“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.

Note: Observe setting of coding “5d”, “5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” group.

f2:0 No time limit*2

f2:1tof2:12

Time limit adjustable from 1 h to 12 h*2.

“Temperature limit for terminating reduced mode”

f8:–5 Temperature limit for terminating reduced mode 23°F (–5°C), see example on page 131. Observe coding “a3”.

f8:+10tof8:–60


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 131.

f9:+10tof9:–60

Limit for raising the set room temperature to the value selected for standard mode, adjustable from 50°F to -76°F (+10°C 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 temperature when changing from operation with reduced room temperature to operation with standard room temperature by 20%. See example on page 131.

fa:0tofa:50


“Duration for raising the set boiler water or supply temperature”

fb:60 Duration for raising the set supply temperature (see coding “fa”) 60 min. See example on page 131.

fb:0tofb:300


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Calling up the Service MenuService Scans

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”


“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”


“Reset all passwords”

“Exit service”

From the home screen tap the following buttons:1. “Menu”

2. “Service”


4. Select the required menu range.

Note:

H “Coding level 2” is only displayed if this level has been enabled: Enter “viexpert” password.

H Tap to return to the “Service main menu”

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Scans Leaving the Service Menu

From the service main menu tap the following buttons:

1. “Exit service”

2. Confirm “Terminate service?” with OK.

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:

1. “Menu”

2. “Service”


4. “Change passwords”

5. “Service level” or “Coding level 2”

6. Enter current password.

Resetting all Passwords to Factory Settings


1. Request the master password from the Technical Service at the Viessmann Group.

2. “Menu”

3. “Service”


Note: The system exits the service menu automatically after 30 min.

7. Confirm with OK.

8. Enter new password.

9. Tap OK twice.

New password for “Service main menu”:

New password for “Coding level 2”:

5. “Change passwords”

6. “Reset all passwords”

7. Enter master password. This must be requested from the service hotline.

8. Confirm twice with OK.

Scanning Operating Data

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.

For further information on operating data, see chapter “Brief scan”.

Note:“- - -” appears on the display if a scanned sensor is faulty.


1. “Menu”

2. “Service”


4. “Diagnosis”

5. Select required group, e.g. “General”.

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.


1. "Menu"

2. "Service"

3. Enter "viservice" password.

4. "Diagnosis"

5. "Reset data"

6. Select required value or "All details".

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Scans

Brief Scan


1. “Menu”

2. “Service”


4. “Diagnosis”

5. “Short query”

1 2 3 4 5 61: System schemes 01 to 10 Control unit software version Software version, programming unit2: 0 0 0 Appliance identification CU-ID3: 0 0 Number of KM BUS participants Software version

Solar control module type SM14: 0 0 0 0 0 05: 0 0 0 0 Software version,

AM1 extensionSoftware version, EA1 extension

6: Connection on plug aVD.1/2 0: Contact open1: Contact closed

Connection on plug aVD.2/3 0: Contact open1: Contact closed

0 0 0 0

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.

7: LON subnet address/system number LON node address 0 08: SNVT config.

0: Auto1: Tool

Software versionCommunic.coproc.

Neuron ChipSoftware version

Participant number

Heating circuit HC1 Heating circuit HC2 Heating circuit HC39: Remote control

0: Without1: Vitotrol 200A2: Vitotrol 300A

Software versionRemote control

Remote control0: Without1: Vitotrol 200A2: Vitotrol 300A


Remote control0: Without1: Vitotrol 200A2: Vitotrol 300A


10: 0 0 0 0 0 011: 0 0 Software

version,extensionfor heating circuits 2and 3 withmixing valve

0 Softwareversion,extensionfor heating circuits 2and 3 withmixing valve

0

Note: The displays in fields 3 and 5 are the same.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Scans


1. “Menu”

2. “Service”


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

Close

“Htg circ pump HC3” ON Actuator at output gS M3

“Mixing valve HC3” Open Actuator at output gS M3

Close

Note: Before an actuator is selected, all actuators are switched off.The actuators listed in the table can be tested at the relay outputs subject to system equipment level and control unit configuration (lead control or service control).

“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 controlmodule, type SM1 set to min. speed.

“Solar circ pump max” ON “Solar circ pump min” On Solar circuit pump at output sF at solar controlmodule, type SM1 set to max. speed.

“SM1 output 22” ON Actuator at output sS at solar control module type SM1

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).

Information regarding the mixing valve motor rotational direction.

Carrying Out an Actuator Test

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Service Scans Checking Sensors


1. “Menu”

2. “Service”


Maintenance Display

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


1. “Menu”

2. “Service”


4. “Service functions”

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.

4. “Diagnosis”

5. Select group.

6. Scan actual temperature of the relevant sensor.

Set limits in coding “21” and “23” in the “Boiler” group.Once these values have been reached, “Service” and symbol appear on the display.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Troubleshooting

Fault Display

In the event of a fault, the red fault display flashes at the control unit. The display shows symbol and “Fault”.

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.


1. “Menu”

2. “Service”


4. “History of faults”

5. Call up further information in the relevant fault with ?.

6. Tap “Reset” to delete the list.

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Boiler System Fault CodesTroubleshooting

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.

H Without DHW tank: Boiler is regulated by the temperature controller.

Short circuit, boiler water temperature sensor

Check boiler water temperature sensor.

38 H With DHW tank: DHW pump ON, boiler is maintained at set tank temperature.

H Without DHW tank: Boiler is regulated by the temperature controller.

Lead break, boiler water temperature sensor

Check boiler water temperature sensor.

40 Mixing valve is being closed. Short circuit, supply temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).

Check supply temperature sensor.

44 Mixing valve is being closed. Short circuit, supply temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).


48 Mixing valve is being closed. Lead break, supply temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).


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Boiler System Fault Codes (continued)

Troubleshooting

Displayedfault code


4c Mixing valve is being closed. Lead break, supply temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).


50 Tank loading pump on:DHW temperature target = set supply temperaturePriority control is cancelled.

Short circuit, tank temperature sensor 1

Check tank temperaturesensor.

52 Control mode Short circuit, supply temperature sensor low loss header.


58 Tank loading pump on:DHW temperature target = set supply temperaturePriority control is cancelled.

Lead break, DHW tanktemperature sensor 1.

Check DHW tank temperature sensor.

5a Control mode Lead break, low loss header supply temperature sensor.

Check supply temperature sensor (see page 186).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, temperaturesensor aJB.

Check temperature sensor.

78 Shunt pump constantly ONWith 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


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 connection cable and sensors (A and B), replace sensors if required.

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Troubleshooting

Displayedfault code


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 sensor (A or B), burner control unit

Check connection cable and sensors (A and B), replace sensors if required.

88 Burner control unit in a fault state Lead break, boiler water temperature sensor, burner control unit


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 sensoraÖ, connection at solar control module, type SM1.

Check temperature sensor aÖ (see separate installation and service instructions).

92 No solar DHW heating. Short circuit, collectortemperature sensor, connection of temperature sensor & at solar control module, type SM1 or sensor at S1 of the Vitosolic.

Check sensor at the solar control unit (see separate installation and service instructions).

93 Control mode. Short circuit, temperature sensor,connection at S3 of the Vitosolic.


94 No solar DHW heating. Short circuit, DHW tank temperature sensor, connection of temperature sensor % at solar 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 sensoraÖ, 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 temperaturesensor, connection of temperature sensor & at solar control module, type SM1 or sensor at S1 of the Vitosolic.


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Troubleshooting

Displayedfault code


9b Control mode Lead break, temperature sensor, connection to S3 of the Vitosolic.


9c No solar DHW heating. Lead break, DHW tank temperaturesensor, connection of temperature sensor % at solar control module, type SM1 or sensor at S2 of the Vitosolic.


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.







a7 Control mode Programming unit fault Replace the programming unit.

ab Control mode, DHW tank may be cold

Tank loading system configura-tion 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.

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Troubleshooting

Displayedfault code


b6 Constant mode Invalid hardware recognition Check coding address “92” in the “General” group;

H 161: Single boiler system

H 190: Cascade control unit

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 withoutremote 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 withoutremote control

Communication error, Vitotrol remote control unit, heating circuit with mixing valve M2 (heating circuit 2)


be Control mode withoutremote control

Communication error, Vitotrol remote control unit, heating circuit with mixing valve M3 (heating circuit 3)


bf Control modeNo communication via LON

Incorrect LON communication module.

Replace LON communication module.

c1 Boiler cools down External safety equipment at plug aBÖ.

Check connection and externalsafety 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.

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Troubleshooting

Displayedfault code


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 modeNo communication via LON, boiler at a configurable 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 36). 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.





da Control mode without room influence.

Short circuit, room temperature sensor, heating circuit without mixing valve A1 (heating circuit 1).

Check room temperaturesensor (see page 186).

db Control mode withoutroom influence

Short circuit, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).

Check room temperaturesensor (see page 186).

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Troubleshooting

Displayedfault code


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 186).

dd Control mode without room influence.

Lead break, room temperature sen-sor, heating circuit without mixing valve A1 (heating circuit 1).


de Control mode without room influence.

Lead break, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).


df Control mode without room influence.

Lead break, room temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).


Displayedfault code


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.


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.

E4 Burner shuts down Multiple detection of undervoltage with return and renewed undervoltage.

Check the power supply.


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.

Burner Fault Codes

Fault display on the display interface of the control unit.

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Burner Fault Codes (continued)

Troubleshooting

Displayedfault code


F2 Burner control unit in a fault state; system cools down.

Excessive boiler water temperature.

Wait until the boiler water temperature falls below the maximum permissible boiler water temperature. If the burner fan is active check sensor 3A/3B. If the burner fan is not active check sensor 15A/15B.Reset burner control unit.

F3 Ionization flame monitor reports faulty flame signal during start-up 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).


Gas valve does not open. Check connecting cable; check gas valve and replace if required.


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).

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Burner Fault Codes (continued)

Troubleshooting

Displayedfault code


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 backed up; air pressure switch hose faulty; connecting hose leaking.

Remove flue gas back pressure; check if condensate backed 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.

F8 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).

F9 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 set value.

Replace fan or burner control 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).

Fault message to the burner control unit:

Note: If LON participant faults occur, “Fault participant”... is displayed.

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Tank, supply and room temperature sensors

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

Sensors

IMPORTANT

Tank, supply and room temperature sensorNote: The supply temperature sensor can be used as a contact or immersion temperature sensor.

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.

Viessmann NTC 10 kΩ (blue ID label)

Temperature

Res

ista

nce

in k

ohm

s

Viessmann NTC 10 kΩ

Temperature

Res

ista

nce

in k

ohm

s

Outdoor temperature sensor

1. Pull plug !.

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.

Troubleshooting

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Burner Control Unit

Display and programming unitA 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.

The display comprises four elements of seven segments each. Four buttons enable adjustments to be made at the different operating levels.

A Status display B Service display C Reset buttonD LEDs, from left: heat demand, flame, maintenance and fault.F Selection buttonE/G Cursor button

Operating displayIn 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 195. You can exit at any time by pressing and holding the reset button R C for 0.5 to 10 seconds.

Idle state check System tests

Fan ramp-up

Pre-purge

Standby

Section start-up after power supply is switched ON.

Gas valve and/or relay test

Burner Control Unit

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Burner Control Unit (continued)

Burner Control Unit

Ignition Safety time Flame established

Pre-ignition

Flame stabilization

Operation with flame

ReheatPost-purge

Maintenance program no air pressure

Maintenance programno gas pressure ormains under voltage

Forced ventilation when no flame was recognized

Safety shutdowndue to flame tear-off

Operating display (continued)

Safety shutdowndue to reaching maximum boiler water temperature

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Burner Control UnitBurner 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. Y Scroll through Status until “6“ is shown under Status:

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.

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.

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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 Secondary boiler water 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 “ “ flashes.




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.



9. B until “0“ is shown under Service.


Burner Control Unit

Menu item “6“ is used to change the following operating parameters:

Sub-menu Item

Parameter Units/Scale Factory set condition

1 Maximum operational input % of rated input 100%

2 Gas type 0=NG (natural gas)1=LPG (liquid propane gas)

Coding card dependent


4 Maximum boiler water temperature from 41°F to 260°F (5°C to 127°C) 203°F (95°C)

5 Integral threshold value of controller In K min from 1 to 255 30 K min

6 Runtime optimization 0=minimum pause1=integral method

1


8 Behavior in case of low gas level 0=delayed lockout fault shutdown 1= delayed safety shutdown

0

0 Reset all operating parameters to their factory set condition.

-- --

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Burner Control UnitBurner Control Unit (continued)

Example: to set the maximum operational burner input to between 0 and 100%, press the following buttons:



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 93 and 94.

6. S to confirm. If applied successfully, “1“ will be shown under Service, “0“ if it failed.


To reset all operating parameters to factory settings,press the following buttons:1. S longer than 2 seconds “ “ flashes.




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.


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 %.

Press the following buttons:

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.

Resetting Operating Parameters to Factory Settings

Manual Mode and Service Display

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Burner Control Unit Flow DiagramBurner Control Unit

Sys

tem

Sta

rt

Input evaluation

Rel

ay t

est

Sta

rt-u

pO

pera

tion

Shu

tdow

nW

ait

stat

eEr

ror

stat

e

Subsequent state depends on the parameterization of the valve test.

Output activation

Non

-val

uate

d in

put

Inpu

t m

ust

be a

ctiv

e fo

r co

ntin

ued

oper

atio

n

Inpu

t m

ust

be p

assi

ve f

or c

ontinu

ed o

pera

tion

Sig

nal c

hang

e is

exp

ecte

d fo

r co

ntin

ued

oper

atio

n

Out

put

is a

ctiv

e

Val

uation

is p

erfo

rman

ce-li

nked

Phas

e

Air

pres

sure

sw

itch

1LD

W1

Gas

pre

ssur

e sw

itch

1G

DW

1

Air

pres

sure

sw

itch

2LD

W2

Fan

spee

d

Flam

e

Req

uire

men

t

Gas

val

ve V

1

Gas

val

ve V

2

Aux

iliar

y va

lve/

Ser

vom

otor

Flue

gas

dam

per

Igni

tion

Fan

Faul

t m

essa

ge o

utpu

t

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Burner Control Unit

State description:

Burner Control Unit Flow Diagram (continued)

Phase Display Description Duration

System start “A” System start 10 seconds

Fan ramp-up, system start max. 20 seconds

Forced ventilation, system start 20 seconds

Relay test ”P“ 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

Standby ”0“ Standby 0 ... seconds

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

“4” Pre-ignition 2 seconds

“5” Ignition safety time 2.3 seconds

Flame detection safety time max. 0.51 second

Operation “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

Shutdown “8” Reheat, test WD2 min. 10 seconds

max. 60 seconds

Fan ramp-up, post-purge max. 20 seconds

Post-purge 10 seconds

Waiting ”U“ Waiting for restart 5 minutes

”C“ Waiting mains, gas pressure 5 minutes

Fault states “9” Forced ventilation fault 20 seconds

“10” Flame tear-off 0 ... seconds

“11” Safety shutdown 0 ... seconds

“F” Fault shutdown 0 ... seconds

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Faults

Fault displayThe 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.

A Fault code of the most recent fault (see table from page 195)

1. Correct the fault. For fault codes and measures, see from page 195. Carry out measures in the indicated order.

2. Press reset button R for longer than 0.5 seconds The operating display is shown again and the burner control unit is reset.

Fault memoryThe 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:




4. Y/B to scroll through the fault memory display.

Service Description

1 Display fault codes

2 Detail fault codes

3 Clear fault memory

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:




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.


Burner Control Unit

AFb

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.

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Fault Codes

Displayed Fault Code

System Characteristics 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, burnercontrol 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, burnercontrol 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, secondary boiler water temperature sensor (A or B), burner control unit

Check lead and sensors (A and B), replace sensor if required


Sensor drift, secondary boiler water temperature sensor (A or B), burner control unit



Lead break, boiler water temperature sensor, burnercontrol unit

Check lead and dual sensor; replace sensor if required


Lead break, secondary boiler water temperature sensor (A or B), burner control unit


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 d0 Burner control unit in a faultstate

Simultaneous selection ofmultiple gas types at theburner control unit via plug lÖ

Check line, check wiring, replaceburner control unit, if required.

F E1 Gas pressure switch 2, GDW2 activated (closed on pressure rise)

1st gas valve seat leaking/GDW2. Gas pressure switch 2activated/burner test firing valve closed.

Check setting of gas pressureswitch 2; check connecting cable;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 setting of gas pressureswitch 2; check connecting cable;replace gas valve

F E2 Shortage of gas to gas pressureswitch 2; valve leak test

Gas valve does not open;gas valve leaking; gaspressure switch 2 faulty.

Replace gas valve

General process faultsFault 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.

Burner Control Unit

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Burner Control UnitFault Codes (continued)



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

F E7 Burner control unit in a faultstate

Short circuit on boiler temperature sensor 2, burnercontrol unit

Check connecting cable and dualsensor; replace sensor if required.


Sensor drift on boiler temperature sensor 2, burnercontrol unit



Lead break, boiler temperaturesensor 2, burner control unit


F EA Burner control unit in a faultstate

For boilers with multiple gas types, 1 or more main gas valves leaking.

Check connection line and maingas valves, replace if required.

F Eb Burner blocked Burner not enabled by externalblocking device

Check blocking device, e.g. fluegas damper.

F 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

F 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

F F0 Emergency operationaccording to internaldefault

Communication error KM BUS burner control unit

Check the KM BUS cableplug for firm seating;check all KM BUS cables

F F2 Burner control unit ina fault state; systemcools down

Excessive boilerwater temperature

Wait until the boiler water temperature falls below the maximum permissible boiler water temperature. If the burner fan is active check sensor 3A/3B. If the burner fan is not active check sensor 15A/15B.Reset burner control unit.

F F3 Ionization flame monitor reports faulty flame signal during start-up or after the post-purge

Gas valve leaking (flame present); incorrect coding card

Check ionization path; replace coding card; replace gas valve

F F4 No flame formation during safety time; ionization flame monitor reports no flame signal

Ionization electrode incorrectly adjusted; ionization electrode not plugged in. Ground fault of electrode or cable

Insert plug of ionization electrode; check cables; adjust ionization electrode (see page 114)

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Fault Codes (continued)




Ignition electrode not set correctly; electrodes grounded; ignition unit faulty; burner control unit faulty

Adjust ignition electrodes (see page 114); replace ignition unit; replace burner control unit


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 connecting cable faulty, solenoid valve faulty, burner control unit output relay faulty

Replace connecting cable; replace servomotor; replace solenoid valve; replace burner control unit

F F4 No flame builds during safety time; ionization flame monitor reports no signal

Incorrect gas type selected Adjust gas type (see page 190)


Gas valve does not open Check the connecting cable; check the gas valve and replace if required


Combustion characteristics not ideal

Adjust the burner (see pages 93 and 94, 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 shows no air pressure, fan does not operate

Air pressure switch 1, LDW1 faulty, incorrectly connected or 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

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 93 and 94)

Burner Control Unit

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Burner Control UnitFault Codes (continued)

Internal system fault Internal system faults are created if a fault-free program sequence can no longer be ensured.

Displayed Fault Code System Characteristics Cause Measures

F F9 Fan not running; fan speed not reached

Fan faulty; cables are faulty or broken

Check cables; replace fan if required

F F9 Status duration too long, fan ramp-up

Internal fault; fan cannot reach its set value

Replace fan or burner control unit

F F9 Varying fan speed Fan faulty, cable “a-ÖA“ faulty or broken

Check cable; replace cable “a-ÖA“ or fan if required

F F9 No fan feedback Fan faulty; external power supply to fan not connected or faulty; cable “a-ÖA“ faulty or broken; fan blocked (possibly by a foreign object)

Check cable “a-ÖA“, check external power supply; replace cable or fan; remove foreign object

F FA Fan runs without demand; burner control unit in a fault state

Fan has not stopped; cable “a-ÖA“ faulty; fan faulty; burner control unit faulty

Wind influence on fan; check flue outlet and fan; replace cable “a-ÖA“, replace fan; replace burner control unit

F Fb Burner not starting. Combustion chamber pressure too high; burner control unit in a fault state

Flue gas path or condensate path blocked off. Excessive combustion chamber pressure (air pressure switch 2, LDW2)

Check flue gas path or condensate path and clean if required

F Fb Burner not starting. Combustion chamber pressure too high; burner control unit in a fault state

Motorized burner damper does not open/close

Check motorized burner damper

F E5, F EC, F Ed, F Fd, F FF

Fault around burner control unit

Internal system fault and EMC

Reset burner control unit. Replace the burner control unit if the fault persists.

Faults Without Fault Display

Fault Cause Measures

Combustion fault through pulsation

Excessive gas input 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.

Thermoacoustics/ combustion noise

Incorrect CO2 settings; insufficient or excessive air

Adjust burner in accordance with the details on pages 93 and 94.

CO2 content too low Incorrect setting Check that burner has been adjusted and adjust burner in accordance with the details on pages 93 and 94.

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.

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Burner Control Unit Connection Diagram

For CA3 2.5 and 3.0 boilers

LegendA Boiler temperature sensor 1 §AB Boiler temperature sensor 2 §B C Secondary boiler water temperature sensor 1 aGAD Secondary boiler water temperature sensor 2 aGBE Overfire pressure switch acAA (APS2)F Fan motor with PWM control and feedback a=ÖA

G Inlet gas pressure switch ayA GDW1H Inlet fan pressure switch acA (APS1) K Gas pressure switch (outlet pressure at first valve seat) kJ GDW2L Burner display and programming unit

M Flame sensor aAN Solenoid valveO Burner damperP Ignition unit gFQ Gas valve V1 dG R Gas valve V2 dHS Vitotronic control unitT AC-EMI suppression filter deviceU Message: Air damper openF1/F2 Fuse

CAUTION Provide disconnect means and overload protection as required.

WARNINGDisconnect power inside the boiler junction box, before servicing boiler.


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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Connection and Wiring Diagrams

Burner Control Unit Connection Diagram

CAUTION Provide disconnect means and overload protection as required.

WARNINGDisconnect power inside the boiler junction box, before servicing boiler.

LegendA Burner control unit interface VUC 310/baseB Flame sensor aAC Vitotronic control unit D Ignition burner inlet damper E Ignition unit gFF Gas valve V1 dG G Gas valve V2 dH H Fan motor with PWM control and feedback a=ÖA

I Boiler temperature sensor 1 §A J Boiler temperature sensor 2 §B

K AC-EMI suppression filter deviceL Secondary boiler water temperature sensor 1 aGA M Secondary boiler water temperature sensor 2 aGB N Inlet fan pressure switch acA (APS1) O Overfire pressure switch acAA (APS2)P Inlet gas pressure switch ayA GDW1Q Gas pressure switch (outlet pressure at first valve seat) kJ GDW2R Burner damper S Burner display and programming unitF1/F2 Fuse

For CA3 3.5 to 6.0 boilers

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Boiler Connections


LegendA Supply temperature sensors heating circuits M2/M3B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connectionsD Boiler power supply connectionE Pumps/mixing valve connectionsF Disconnect switch with lockout provisionG Vitocom 100 LAN1

Connection overview for CA3 2.5 and 3.0 models

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Connection and Wiring Diagrams

Boiler Connections

Connection overview for CA3 3.5 to 6.0 models

LegendA Supply temperature sensors heating circuits M2/M3B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connections

D Boiler power supply connectionE Pumps/mixing valve connectionsF Internal disconnect switch (with lockout provision)G Vitocom 100 LAN1

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Overview

LegendA1 PCB extension for heating circuits 2 and 3 with

mixing valve, boiler section 1 control onlyA2 PCB, low voltage A3 PCB, 120 V~ A6 Programming unit connection PCBA7 Optolink PCB / emissions test switch

A8 PCB A9 Coding cardA10 LON communication module A11 Power supply unit PCB A12 Programming unit ON/OFF switchA13 Programming unitX Electrical interfaces


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PCB Extension for Heating Circuits 2 and 3 with Mixing Valve

Legend! Outdoor temperature sensor?/§ Supply temperature sensor / common system

supply temperature%A DHW Tank temperature sensor %B DHW tank temperature sensor for tank loading systemaJB Temperature sensor, DHW tank loading system avD External connections

avG KM-BUS participantsavH External connections LON Connecting cable for data exchange (accessory) S3 Emissions test switch V1 Fault display (red) V2 Operating mode display (green) X Electrical interfaces

PCB, Low Voltage

PCB, extension for heating circuits 2 and 3 with mixing valve

? M2/M3 Supply temperature sensorssÖ M2/M3 Heating circuit pumpsfÖ Power supplygS M2/M3 Mixing valve motorsK1-K6 RelayX Electrical interfaces


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LegendsÖ Heating circuit pump

orprimary pump, tank loading system

sA Circulation pump for DHW tank heating (accessory)

sK DHW recirculation pump (on-site)sL Boiler circuit pump or distributor pump (on-site) fÖ Power supply, 120 V/60 Hz fA Burner gÖ Output for central fault messagegS Motor for 3-way mixing valve, primary store

system

aBÖ External connections (remove jumper when connecting)

aBA Safety chain (potential free) aBH Power supply for accessories F MCB/fuse K2-K10 Relays S1 On/off switch X Electrical interfaces

Connection and Wiring Diagrams PCB 120V~

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Parts

Parts Lists

Model No. Serial No. CA3 2.5 Boiler 7769870CA3 3.0 Boiler 7769871

Ordering Replacement Parts:Please provide Model and Serial Number from CSA ratingplate A when ordering replacement parts. Order replacement components from your Viessmann distributor.

CA3 Parts for CA3 2.5 and 3.00001 Vitocrossal 300 CA3 boiler0002 Vitotronic 300 GW6C control panel0003 Boiler enclosure assembly0004 Other Parts

A Rating Plate

Other Parts (not illustrated)0100 Installation Set 0150 Technical literature set

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Parts

Parts Lists (continued)


Ordering Replacement Parts:Please provide Model and Serial Number from CSA rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.

CA3 Parts for Enclosure Assembly0001 Side panel, right top front0002 Side panel, right top rear0004 Side panel, left top0006 Side panel, right bottom0008 Front panel, top0009 Nameplate, “Vitocrossal 300”0010 Nameplate, “Viessmann”0011 Front panel, bottom0012 Rear panel 1, bottom0013 Rear panel 2, bottom0014 Rear panel, top0015 Cover plate0018 Top panel0020 Insulation blanket0021 Cable channel, front0022 Cable channel, rear0024 Cable clasp0025 Side panel, left front bottom0027 Side panel, left rear bottom0028 Cover panel0029 Filter, grill0030 Filter, air0031 Accessory pack, fasteners0032 Access key for control panel

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service PartsParts Lists (continued)

Model No. Serial No. CA3 2.5 Boiler 7769870


CA3 Parts for CA3 2.5 Boiler Assembly0002 Boiler section, 1.25 MMBH0003 Gasket, 30 x 20 L=15000004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0010 Accessory pack, boiler sections, 1.25 MMBH and 1.5 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 10” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0017 Accessory pack for supply, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gaskets0028 Connection pipe 2, NG/LP with gaskets0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harnesses and Sensors 0036 CA3 Cylinder Burner 1.25 MMBH

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CA3 Parts for CA3 3.0 Boiler Assembly0002 Boiler section0003 Gasket, 30 x 20 L=1500 0004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0010 Accessory pack, boiler sections, 1.25 MMBH and 1.5 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 10” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0017 Accessory pack for supply, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gaskets0028 Connection pipe 2, NG/LP with gaskets0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harnesses and Sensors 0036 CA3 Cylinder Burner 1.5 MMBH

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CA3 Parts for Burner Assembly, 1.25 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis, compact0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control 0013 Fan, G3G200 120/1/600014 Gasket, fan0015 Venturi mixing pipe0016 Gas valve, V4734C1010-11000017 Servomotor, burner damper STA0018 Linkage, M5, burner damper0019 Flange, 1¼”, gas valve0020 O-ring, 52x3.5, gas valve0021 Connection pipe, fuel NG/LP0022 Gasket, triple electrode0023 Hose set0024 Installation instructions compact burner0025 Orifice with gasket, NG0026 Gasket, fan0027 Fan adaptor0028 Burner tube kit, D2450029 Flange, 1¼”, gas valve0030 2/2 way solenoid valve

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CA3 Parts for Burner Assembly, 1.5 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis, compact0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control 0013 Fan, G3G200 120/1/600014 Gasket, fan0015 Venturi mixing pipe0016 Gas valve, V4734C1010-11000017 Servomotor, burner damper STA0018 Linkage M5, burner damper0019 Flange, 1¼”, gas valve0020 O-ring, gas valve, 52x3.50021 Connection pipe, fuel NG/LP0022 Gasket, triple-electrode0023 Hose set0024 Installation instructions compact burner0025 Orifice with gasket, NG0026 Gasket, fan0027 Fan adaptor0028 Burner tube kit, D2450029 Flange, 1¼”, gas valve0030 2/2 way solenoid valve

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CA3 Parts for Control Panel, Vitotronic 300, GW6C 0001 Master-Display0002 Vitotronic 300, GW6C boiler and system control0003 Junction Box

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CA3 Parts for Master-Display Assembly0001 Control console, GW6C0002 Rear housing, master display0003 Programming unit, Vitotronic 200 HI9300004 Circuit board, SA168 A100005 Flat cable, 16-pole0006 Harness, master power0007 Harness, relay0008 Covers, sliding, left/right



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CA3 Parts for Connection Enclosure Assembly0001 Control unit, module0002 Cover, motherboard0003 Extension module, MV 2+30004 Motherboard, low voltage, MB2000005 Circuit board, CU102-A60.XXX touch0006 Motherboard, 120/1/60, MB2010007 Circuit board, power supply, SP1020008 Circuit board, LON, IU100-B100009 Rear housing, connection enclosure0010 Control panel, without AHL+FHL, 120/1/600011 Switch, 2-pole, on/off0012 Fuse holder cover0013 Fuse holder0014 Fuse, T6.3A/250V (set of 10)0015 Sensor #1, outdoor, NTC0016 Sensor #5, DHW, immersion NTC0017 Sensor #2/#17, supply/return, strap-on NTC0018 Harness, heating circuit expansion 156/40A0019 Cable, 1M shielded, 2 x RJ45-steward0020 Connecting cable (7M), LON RJ450021 LON terminal end resistor (set of 2)0022 Accessory pack, low voltage plugs0023 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 #143,145,1460030 Coding plug0031 Programming unit, Vitotronic 200 HI9300032 Control, with sub-base, adaptor and cabling0033 Connecting cable, ETS0034 Switch, 1-pole, ETS0035 Flat cable, 16-pole

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CA3 Parts for Junction Box Assembly0001 Vitocom 100 LAN1 without communication module0002 Disconnect switch, 690/3/400003 Sealing grommet, M630004 Receptacle, CA/US0005 Relay, K3-14ND10, 120V0006 Terminal block, 3-pole0007 Terminal block, PT 2.50008 Terminal block, PT 160009 Fuse holder0010 Fuse, 2.0A/250V (set of 10)0011 Circuit breaker, 16A0012 Circuit breaker, 10A0013 Relay, 24-240V 8A, SPDT time delay0015 Power relay, 120V 10A 3PDT0016 Power relay, 120V 10A DPDT0017 Vitogate 300 BN (optional accessory)0018 Power supply, 24VDC 0.75A (optional accesory)

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CA3 Parts for Burner Control Subassembly0001 Burner control, VUC310-C10.0040002 Programming unit, HI201-C01.001 with LED0003 Harness “11”, ionization/ground0004 Cable, gas pressure switch “2”0005 Harness “54”, ignition transformer0006 Harness, step motor0007 Harness “111”, gas pressure0008 Harness “35/36”, gas valve0009 Harness “100A”, motor0010 Harness “100”, fan0011 Cable, “131A”, sensors and air pressure switch0012 Air pressure switch 1 with cable0013 Air pressure switch with 131A cable0014 Cable, fuel conversion0015 Harness, burner shut-off0016 Accessory pack, plugs #41,90,151,1910017 Suppression filter device AC EMI0018 Plug, 3-pole, RST25I3 (each)0019 Harness “38”, bypass

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CA3 Parts for Burner Harness and Sensors0001 Fixed high limit for supply, central0002 Sensor for flue gas, central0003 Cable, gas pressure switch0004 Burner cable set, 120V, KM-BUS0005 Cable, double sensor0006 Secondary boiler water temperature sensor0007 Sensor #3A / #3B, double0008 Sensor #1, outdoor, NTC

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CA3 Parts for Other Parts0001 Touch-up, spray paint Vitotec, silver0002 Touch-up, paint stick Vitotec silver0003 Installation and service instructions CA3 Single-Fuel

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Ordering Replacement Parts:Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor.

Parts for CA3 3.5 and 4.0 Boilers0001 Vitocrossal 300 CA3 boiler0002 Vitotronic 300 GW6C control panel0003 Boiler enclosure assembly0004 Other Parts

A Rating Plate


220

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CA3 Parts for Enclosure Assembly0001 Side panel, right top front0002 Side panel, right top rear0004 Side panel, left top0006 Side panel, right bottom0008 Front panel, top0009 Nameplate, “Vitocrossal 300”0010 Nameplate, “Viessmann”0011 Front panel, bottom0012 Rear panel 2, bottom0013 Rear panel 1, bottom0014 Rear panel 2, top0015 Cover plate 20016 Rear panel 1, top0017 Cover plate 10018 Top panel0020 Insulation blanket0021 Cable channel, front0022 Cable channel, rear0024 Cable clasp, 930 mm0025 Side panel, left front bottom0027 Side panel, left rear bottom0028 Cover panel0029 Filter, grill0030 Filter, air0031 Accessory pack, fasteners0032 Access key for control panel

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CA3 Parts for CA3 3.5 Boiler Assembly0001 Boiler section, 1.5 MMBH0002 Boiler section, 2.0 MMBH0003 Fiber rope seal, 25x15x1500 mm0004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0010 Accessory pack, boiler section, 1.25 MMBH and 1.5 MMBH0011 Accessory pack, boiler section, 2.0 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 12” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0018 Accessory pack, DN650019 Flow regulator 1, DN650020 Accessory pack, DN650021 Flow regulator 2, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gasket0028 Connection pipe 2, NG/LP with gasket0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP with gasket0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harness and Sensors 0034 CA3 Cylinder Burner 2.0 MMBH 0035 CA3 Cylinder Burner 1.5 MMBH

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CA3 Parts for CA3 4.0 Boiler Assembly0002 Boiler section, 2.0 MMBH0003 Fiber rope seal, 25x15x1500 mm0004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0011 Accessory pack boiler section, 2.0 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 12” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0017 Accessory pack for supply, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gaskets0028 Connection pipe 2, NG/LP with gaskets0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP with gaskets0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harness and Sensors 0034 CA3 Cylinder Burner 2.0 MMBH

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CA3 Parts for Burner Assembly, 1.5 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control 0013 Servomotor, inlet damper STA0014 Fan, G3G200 120/1/600015 Gasket, fan0016 Inlet damper0017 Linkage M5, inlet damper0018 Venturi mixing pipe0019 Gas valve, V4734C1010-11000020 Servomotor, burner damper STA0021 Linkage M5, burner damper0022 Flange, 1¼”, gas valve0023 O-ring, gas valve, 52x3.50024 Connection pipe 2, with shut-off0025 Gasket, triple-electrode0026 Compensation hose set, air pressure0027 Installation instruction compact burner0028 Orifice with gasket, NG0029 Gasket, fan0030 Fan adaptor0031 Burner tube kit, D2450032 Flange, 1¼”, gas valve

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CA3 Parts for Burner Assembly, 2.0 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control 0013 Servomotor, inlet damper STA0014 Fan,120/1/600015 Gasket, fan0016 Inlet damper0017 Linkage M5, inlet damper)0018 Venturi mixing pipe0019 Gas valve, V4734C1010-11000020 Servomotor, burner damper STA0021 Linkage M5, burner damper0022 Flange, 1¼”, gas valve0023 O-ring, gas valve, 52x3.50024 Connection pipe 1 with shut-off0025 Gasket triple-electrode0026 Compensation hose set, air pressure0027 Installation instructions compact burner0028 Burner tube kit, D2450029 Flange, 1¼”, gas valve

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CA3 Parts for Control Panel, Vitotronic 300, GW6C0001 Master-Display0002 Vitotronic 300, GW6C boiler and system control0003 Junction Box

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CA3 Parts for Connection Enclosure Assembly0001 Control unit, module0002 Cover, motherboard0003 Extension module, MV 2+30004 Motherboard, low voltage, MB2000005 Circuit board, CU102-A60.XXX touch0006 Motherboard, 120/1/60, MB2010007 Circuit board, power supply, SP1020008 Circuit board, LON, IU100-B100009 Rear housing, connection enclosure0010 Control panel, without AHL+FHL, 120/1/600011 Switch, 2-pole, on/off0012 Fuse holder cover0013 Fuse holder0014 Fuse, T6.3A/250V (set of 10)0015 Sensor #1, outdoor, NTC0016 Sensor #5, DHW, immersion NTC0017 Sensor #2/#17, supply/return, strap-on NTC0018 Harness, heating circuit expansion 156/40A0019 Cable, 1M shielded, 2 x RJ45-steward0020 Connecting cable (7M), LON RJ450021 LON terminal end resistor (set of 2)0022 Accessory pack, low voltage plugs0023 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 #143,145,1460030 Coding plug0031 Programming unit, Vitotronic 200 HI9300032 Control, with sub-base, adaptor and cabling0033 Connecting cable, ETS0034 Switch, 1-pole, ETS0035 Flat cable, 16-pole



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CA3 Parts for Junction Box Assembly0001 Vitocom 100 LAN1 without communication module0002 Disconnect switch, 690/3/400003 Sealing grommet, M630004 Receptacle, CA/US0005 Relay, K3-14ND10 120V0006 Terminal block, 3-pole0007 Terminal block, PT 2.50008 Terminal block, PT 160009 Fuse holder0010 Fuse, 2.0A/250V (set of 10)0011 Circuit breaker, 16A0012 Circuit breaker, 10A0013 Relay, 24-240V 8A SPDT time delay0014 Power relay, 120V 30A0015 Power relay, 120V 10A 3PDT0016 Power relay, 120V 10A DPDT0017 Vitogate 300 BN (optional accessory)0018 Power supply, 24VDC 0.75A (optional accessory)



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CA3 Parts for Burner Control Subassembly0001 Burner control, VUC310-C10.0020002 Programming unit with LED0003 Harness “11”, ionization/ground0004 Harness “VPS87”, gas pressure0005 Harness “54”, ignition transformer0006 Harness, step motor/inlet damper0007 Harness “111”, gas pressure0008 Harness “35/36”, gas valve0009 Harness “100A”, motor0010 Harness “100”, fan0011 Harness sensors0012 Air pressure switch 1 with cable0013 Air pressure switch 2 with cable0014 Air pressure switch with cable0015 Harness, step motor/burner damper0016 Accessory pack, plugs #41,90,151,1910017 Suppression filter device AC EMI0018 Plug, 3-pole, RST25I3 (each)



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CA3 Parts for Other Parts0001 Touch-up, spray paint Vitotec, silver0002 Touch-up, paint stick Vitotec silver0003 Installation and service instructions CA3 single-fuel



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CA3 Parts for CA3 5.0 and 6.0 Boilers0001 Vitocrossal 300 CA3 boiler0002 Vitotronic 300 GW6C control panel0003 Boiler enclosure assembly0004 Other Parts

A Rating Plate



Ordering Replacement Parts:Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor.

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CA3 Parts for Enclosure Assembly0001 Side panel, right top front0002 Side panel, right top rear0003 Side panel, right top mid0004 Side panel, left top0005 Side panel, left top mid0006 Side panel, right bottom0007 Side panel, right mid bottom0008 Front panel, top0009 Nameplate, “Vitocrossal 300”0010 Nameplate, “Viessmann”0011 Front panel, bottom0012 Rear panel 2, bottom0013 Rear panel 1, bottom0014 Rear panel 2, top0015 Cover plate 20016 Rear panel 1, top0017 Cover plate 10018 Top panel0019 Top panel, mid0020 Insulation blanket0021 Cable channel 10022 Cable channel 20023 Cable channel 30024 Cable clasp, 930 mm0025 Side panel, left front bottom0026 Side panel, left mid bottom0027 Side panel, left rear bottom0028 Cover panel0029 Filter, grill0030 Filter, air0031 Accessory pack, fasteners0032 Access key for control panel



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CA3 Parts for CA3 5.0 Boiler Assembly0001 Boiler section, 1.5 MMBH0002 Boiler section, 2.0 MMBH0003 Fiber rope seal, 25x15x1500mm0004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0010 Accessory pack boiler section, 1.25 MMBH and 1.5 MMBH0011 Accessory pack boiler section, 2.0 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 12” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0018 Accessory pack, DN650019 Flow regulator, DN650022 Accessory pack, DN650023 Orifice, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gaskets0028 Connection pipe 2, NG/LP with gaskets0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP with gaskets0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harness and Sensors 0034 CA3 Cylinder Burner 2.0 MMBH 0035 CA3 Cylinder Burner 1.5 MMBH



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CA3 Parts for CA3 6.0 Boiler Assembly0002 Boiler section, 2.0 MMBH0003 Fiber rope seal, 25x15x1500 mm0004 Support bracket 10005 Support bracket 20006 Plug, 1½”0007 Fiber rope seal, 18x2100 mm0008 Sensor well, G½ L=100 with clip0009 Sensor well, G½ L=150 with clip0011 Accessory pack boiler section, 2.0 MMBH0012 Boiler stand0013 Cover with tension gasket0014 Locking band, 12” with gasket0015 Boiler supply header0016 Gasket, PN10 DN2”0017 Accessory pack for supply, DN650024 Boiler return header0025 Accessory pack for return, DN650026 Servomotor, SR230A-50027 Connection pipe 1, NG/LP with gaskets0028 Connection pipe 2, NG/LP with gaskets0029 Gasket, A46x62x20030 Connection pipe 3, NG/LP with gaskets0032 Condensate syphon, G1 1/4 x G1 1/20033 CA3 Burner Harness and Sensors 0034 CA3 Cylinder Burner 2.0 MMBH



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CA3 Parts for Burner Assembly, 1.5 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control0013 Servomotor, inlet damper STA0014 Fan, G3G200 120/1/600015 Gasket, fan0016 Inlet damper0017 Linkage M5, inlet damper0018 Venturi mixing pipe0019 Gas valve, V4734C1010-11000020 Servomotor, burner damper STA0021 Linkage M5, burner damper0022 Flange, 1¼”, gas valve0023 O-ring, gas valve, 52x3.50024 Connection pipe 2, with shut-off0025 Gasket, triple-electrode0026 Compensation hose set, air pressure0027 Installation instruction compact burner0028 Orifice with gasket, NG0029 Gasket, fan0030 Fan adaptor, 2.0 MMBH0031 Burner tube kit, D2450032 Flange, 1¼”, gas valve



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CA3 Parts for Burner Assembly, 2.0 MMBH0001 Burner plate0002 Burner gasket0003 Burner chassis0004 Combustion chamber door refractory0005 Accessory pack, small burner parts0006 Burner tube0007 Gasket, burner tube0008 Electrodes0009 Ignition cable0010 Ignition transformer0011 Coding plug, burner0012 CA3 Burner Control 0013 Servomotor, inlet damper STA0014 Fan,120/1/600015 Gasket, fan0016 Inlet damper0017 Linkage M5, inlet damper0018 Venturi mixing pipe0019 Gas valve, V4734C1010-11000020 Servomotor, burner damper STA0021 Linkage M5, burner damper0022 Flange, 1¼”, gas valve0023 O-ring, gas valve, 52x3.50024 Connection pipe 1 with shut-off0025 Gasket triple-electrode0026 Compensation hose set, air pressure0027 Installation instructions compact burner0028 Burner tube kit, D2450029 Flange, 1¼”, gas valve



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CA3 Parts for Control Panel, Vitotronic 300, GW6C0001 Master-Display0002 Vitotronic 300, GW6C boiler and system control0003 Junction Box



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CA3 Parts for Connection Enclosure Assembly0001 Control unit, module0002 Cover, motherboard0003 Extension module, MV 2+30004 Motherboard, low voltage, MB2000005 Circuit board, CU102-A60.XXX touch0006 Motherboard, 120/1/60, MB2010007 Circuit board, power supply, SP1020008 Circuit board, LON, IU100-B100009 Rear housing connection enclosure0010 Control panel, without AHL+FHL, 120/1/600011 Switch, 2-pole, on/off0012 Fuse holder cover0013 Fuse holder0014 Fuse, T6.3A/250V, (set of 10)0015 Sensor #1, outdoor, NTC0016 Sensor #5, DHW, immersion NTC0017 Sensor #2/#17, supply/return, strap-on NTC0018 Harness heating circuit expansion 156/40A0019 Cable, 1M shielded, 2 x RJ45-steward0020 Connecting cable (7M), LON RJ450021 LON terminal end resistor (set of 2)0022 Accessory pack, low voltage plugs0023 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 #143,145,1460030 Coding plug0031 Programming unit, Vitotronic 200 HI9300032 Control, with sub-base, adaptor and cabling0033 Connecting cable, ETS0034 Switch, 1-pole, ETS0035 Flat cable, 16-pole



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CA3 Parts for Junction Box Assembly0001 Vitocom 100 LAN1 without communication module0002 Switch-disconnector, 690/3/400003 Sealing grommet, M630004 Receptacle, CA/US0005 Relay, K3-14ND10 120V0006 Terminal block, 3-pole0007 Terminal block, PT 2.50008 Terminal block, PT 160009 Fuse holder0010 Fuse, 2.0A/250V (set of 10)0011 Circuit breaker, 16A0012 Circuit breaker, 10A0013 Relay, 24-240V 8A SPDT time delay0014 Power relay, 120V 30A0015 Power relay, 120V 10A 3PDT0016 Power relay, 120V 10A DPDT0017 Vitogate 300 BN (optional accessory)0018 Power supply, 24VDC 0.75A (optional accessory)



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CA3 Parts for Burner Control Subassembly0001 Burner control, VUC310-C10.0020002 Programming unit with LED0003 Harness “11”, ionization/ground0004 Harness “VPS87”, gas pressure0005 Harness “54”, ignition transformer0006 Harness, step motor/inlet damper0007 Harness “111”, gas pressure0008 Harness “35/36”, gas valve0009 Harness “100A”, motor0010 Harness “100”, fan0011 Harness, sensors0012 Air pressure switch 1 with cable0013 Air pressure switch 2 with cable0014 Air pressure switch with cable0015 Harness, step motor/burner damper0016 Accessory pack, plugs #41,90,151,1910017 Suppression filter device, AC EMI0018 Plug, 3-pole, RST25I3 (each)



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CA3 Parts for Other Parts0001 Touch-up, spray paint Vitotec, silver0002 Touch-up, paint stick Vitotec silver0003 Installation and service instructions CA3 Single-Fuel



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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Technical Data

Specifications

Boiler Model CA3 2.5 3.0 3.5 4.0 5.0 6.0Input MBH

(kW) 2500 (733)

3000 (879)

3500 (1026)

4000 (1172)

5000 (1465)

6000 (1758)

Minimum Input MBH (kW)

250 (73)

300 (88)

300 (88)

400 (117)

300 (88)

400 (117)

Output (thermal efficiency) MBH (kW)

2402 (703)

2883 (844)

3363 (985)

3844 (1126)

4805 (1408)

5766 (1689)

Output (combustion efficiency) MBH (kW)

2352 (689)

2832 (830)

3294 (965)

3764 (1103)

4705 (1379)

5646 (1655)

Net AHRI Rating MBH (kW)

2089 (611)

2506 (734)

2924 (856)

3342 (979)

4178 (1224)

5013 (1469)

Combustion efficiency *1 % 94.1 94.1 94.1 94.1 94.1 94.1Thermal efficiency *1 % 96.1 96.1 96.1 96.1 96.1 96.1NG Supply Pressure ”w.c. (max.) 14 14 14 14 14 14

”w.c. (min.) 4 4 4 4 4 4LPG Supply Pressure ”w.c. (max.)

”w.c. (min.)1410

1410

1410

1410

1410

1410

Power Supply Voltage 120 120 120 120 208*2 208*2Phase 1 1 1 1 3 3

Hz 60 60 60 60 60 60Amp. 20 20 20 20 20 20

Overall Boiler Length(including insulation

in. (mm)

90c (2305)

90c (2305)

101f (2581)

101f (2581)

138 (3503)

138 (3503)

and jacketing)Overall Boiler Width(including insulation

in. (mm)

33 (860)

33 (860)

39e (1000)

39e (1000)

39e (1000)

39e (1000)

and jacketing)Overall Boiler Height*4

(including insulationand jacketing)

in. (mm)

78c (2000)

78c (2000)

84 (2131)

84 (2131)

84 (2131)

84 (2131)

Concrete boiler base*3Length in.

(mm)74

(1900)74

(1900)82f

(2100)82f

(2100)114d (2900)

114d (2900)

Width in. (mm)

33(860)

33 (860)

39e (1000)

39e (1000)

39e (1000)

39e (1000)

Thickness in. (mm)

4 (100)

4 (100)

4 (100)

4 (100)

4 (100)

4 (100)

WeightComplete with the burners, control, thermal insulation and jacketing

lb. (Kg)

4388 (1990)

4388 (1990)

4982 (2260)

5093 (2310)

6592 (2990)

7187 (3260)

*1 Tested to ANSI/AHRI standard 1500 Performance Rating of Commercial Space Heating Boilers / DOE Test Procedure 81 FR 89276 / U.S. Standards ANSI Z21.13/CSA 4.9 / AHRI, BTS-2000 Testing Standard Method to determine the efficiency of Commercial Heating Boilers.*2 Requires 208Y/120VAC - 3phase- 60 Hz - 4 wire (L1, L2, L3, N, G) power supply.*3 Concrete boiler pad is required for all installations (refer to page 10 for additional information).*4 Does not include the concrete boiler pad or seismic brackets.

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

A Input capacity after electronic altitude adjustment is made.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Technical Data (continued)

Specifications

Boiler Model CA3 2.5 3.0 3.5 4.0 5.0 6.0Boiler Water Content USG 108 108 151 143 227 218

(L) (410) (410) (570) (540) (860) (825)

Heat Exchanger Surface ft.2 142.7 142.7 170.2 192.5 244.1 288.8(m2) (13.3) (13.3) (15.8) (17.9) (22.7) (26.8)

Maximum Operating Temperature °F (°C)

210 (99)

210 (99)

210 (99)

210 (99)

210 (99)

210 (99)

Maximum Adjustable High Limit °F (°C)

203 (95)

203 (95)

203 (95)

203 (95)

203 (95)

203 (95)

Maximum Operating Pressure psig 160 160 160 160 160 160(bar) (11) (11) (11) (11) (11) (11)

Boiler ConnectionsBoiler supply and return(BS), (BR) (ANSI flanges)

in.(mm)

4(100)

4(100)

4(100)

4(100)

4(100)

6(150)

Safety supply in. 2 2 2 2 2 2Boiler drain in. 2@1b 2@1b 2@1b 2@1b 3@1b 3@1bCondensate drain (barbed fitting) in. c c c c c cGas connection in. 2b 2b 2b 2b 3 3Vent PipeInternal diameter in. 10 10 12 12 16 16

(mm) (254) (254) (306.8) (306.8) (408.4) (408.4)

Combustion Air Internal diameter(for direct vent sealed combustionusing the combustion air intake kit optional accessory)

in.(mm)

10(254)

10(254)

12(306.8)

12(306.8)

16(408.4)

16(408.4)

Flue Gas ValuesTemperature (at a return temperature of 86°F (30°C)at rated input °F 113 113 117 117 122 122

(°C) (45) (45) (47) (47) (50) (50)

at partial load °F 91 91 91 91 91 91(°C) (33) (33) (33) (33) (33) (33)

Temperature (at a return temperature of 140°F (60°C)at rated input °F 167 167 162 162 167 167

(°C) (75) (75) (72) (72) (75) (75)Mass flow rate (of flue gas)at rated input lbs/h 2216 2216 3109 3549 4442 5324

(kg/h) (1007) (1007) (1410) (1610) (2015) (2415)

at partial load lbs/h 267 320 320 425.5 320 425.5(kg/h) (121) (145) (145) (193) (145) (193)

Max. Condensate Flow Ratefor NG and LPG

USG/h(L/h)

24(91)

29(109)

34(129)

38(144)

48(182)

58(220)

Pressureat boiler flue outlet pa

(max.)100 100 100 100 100 100

at rated input “w.c. (max.)

0.4 0.4 0.4 0.4 0.4 0.4

Standby Loss At boiler water temperature158°F (70°C) [room temperature 68°F (20°C)]

BTU/h (W)%

6227(1825)0.25

7469(2197)0.25

8750(2564)0.25

10000(2931)0.25

12500(3663)0.25

15000(4396)0.25

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Boiler Dimensions

Specifications

LegendSA Safety headerKV Boiler supplyLG Natural gas connectionKR Boiler returnAGA Flue gas outlet (vent pipe connection)

CA3 2.5, 3.0, 3.5 and 4.0

CA3 5.0 and 6.0

*1 Heights do not include the concrete pad or seismic brackets. Seismic brackets will add 2e inches (60 mm). See page 10.*2 Applies to KR and KV*3 Applies to LG

DimensionsBoiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0L in. (mm) 7a (187) 6b (161) 7 (173)M*1 in. (mm) 11c (298) 11c (298) 11c (298)N in. (mm) 35 (890) 40 (1015) 44 (1118)O in. (mm) 28e (720) 32a (820) 32a (820)P*1 in. (mm) 14 (357) 14 (357) 14 (357)Q*2 in. (mm) 23c (604) 28f (728) 28f (728)R*3 in. (mm) 23c (604) 29 (733) 29 (737)

DimensionsBoiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0A in. (mm) 90b (2298) 101a (2573) 137c (3496)B in. (mm) 33c (860) 39a (996) 39a (996)C*1 in. (mm) 78c (1999) 84 (2131) 84 (2131)D in. (mm) 85e (2168) 96a (2443) 132b (3366)E in. (mm) 31b (800) 36 (936) 36 (936)F*1 in. (mm) 74 (1879) 79a (2011) 5.0 - 79a (2011)

6.0 - 80b (2040)

G*1 in. (mm) 69b (1762) 74c (1896) 74c (1896)H*1 in. (mm) 60b (1533) 64a (1629) 64a (1629)I*1 in. (mm) 26a (667) 26a (665) 26a (665)J in. (mm) 12 (325) 9b (237) 9b (238)K in. (mm) 71e (1813) 79a (2013) 111d (2823)

Note: dimensional tolerance of a in. ( 5 mm)

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Inspection and Maintenance

Counter reading

USG

Fill and make-up water

USG

Total quantity of water

USG

Total hardness

Feed water Boiler water

pH-value Date

Requirements for Water Conditions

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Maintenance RecordInspection and Maintenance

Maintenance Schedule

The following chart is an overview of scheduled service steps.

Regular service work ensures reliable, energy-efficient, and environmentally friendly operation.

IMPORTANTKeep 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.

The boiler must be cleaned at least once a year by a qualified heating technician or service agency.

IMPORTANT

Setting and Test Values Commissioning Maintenance/Service

Static Pressure mbar (”w.c.) Section 1 Section 2 Section 3 Section 1 Section 2 Section 3

Supply Pressure (running pressure)

for natural gas NG mbar (”w.c.)

for liquid propane gas LPG mbar (”w.c.)

Check gas type

Carbon Dioxide Content CO2

■ at the upper rated heating output actual % by vol.

set % by vol.

■ at the lower rated heating output actual % by vol.

set % by vol.

Oxygen Content O2

■ at the upper rated heating output actual % by vol.

set % by vol.

■ at the lower rated heating output actual % by vol.

set % by vol.

Carbon Monoxide Content CO actual ppm

set ppm

Flue Gas Temperature (gross) 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.)

250

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service Inspection and Maintenance

Frequency Performed by Service

Monthly Owner / Operator

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.

Annually Owner / Operator

Ensure service work/test is conducted at least annually by qualified personnel, and that any deficiencies are corrected immediately.

Heating Technician

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.

Periodically 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.

Maintenance Schedule (continued)

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