Viessmann VITOCROSSAL 300 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3B, 187 to 635 kW
Gas condensing boiler
VITOCROSSAL 300
5800301 GB 9/2018 Dispose after installation.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
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1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
System examples .................................................................................. 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
3. Installation sequence Siting and levelling the boiler ................................................................. 8
Converting the boiler door opening ........................................................ 10
Assembly after dismantling .................................................................... 10
Connections on the heating water side .................................................. 12
Connections on the flue gas side ........................................................... 13
■Flue outlet and siphon ........................................................................ 13
Fitting the thermal insulation .................................................................. 14
■Boiler shell thermal insulation ............................................................. 14
■Thermal insulation mat, front .............................................................. 15
■Thermal insulation mats, back ............................................................ 16
■Front fixing rails, retaining bracket and cross braces ......................... 17
■Rear and central fixing rails ................................................................ 18
■Corner rails ......................................................................................... 20
■Side panels and burner cables ........................................................... 21
■Front panels ........................................................................................ 22
■Boiler door .......................................................................................... 23
■Back panels, covers, cap and boiler water temperature sensor ......... 26
■Top panels and reinforcement struts .................................................. 27
■Preparing the control unit installation ................................................. 28
■Type plate ........................................................................................... 29
Connecting the neutralising system ....................................................... 30
Making the safety connections .............................................................. 30
Mounting the burner ............................................................................... 31
Pressure switch ..................................................................................... 31
■Pressure switch .................................................................................. 31
Fuels ...................................................................................................... 31
Commissioning and adjustment ............................................................. 32
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Disposal of packaging
5800301

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Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Product information
Vitocrossal 300, type CT3B
■Fuel: Natural gas E and natural gas LL
■Rated heating output 187 to 635 kW
■Permissible operating pressure for the heating sys-
tem: 6 bar (0.6 MPa)
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
5800301

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D
200
a
b
500
500 (400)
500 (50)
(400)
A B
C E
Fig. 1
ABoiler
BBurner
CAdjustable anti-vibration feet
D/EAnti-vibration boiler supports
Note
The hinge pins can be repositioned so that the boiler
door opens to the left.
Dimensions in brackets are minimum clearances.
C
100
20
31
M16
Fig. 2
D
c
d
e
Fig. 3
d
c
e
E
Fig. 4
Clearance dimensions
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Rated heating output kW 187 248 314 408 508 635
amm 930 1000 1100 1500 1500 1500
bmm Observe the installed burner length
Adjustable anti-vibration boiler feet C
Permissible load kg 1200
Number pce 4
Anti-vibration boiler supports
Permissible load kg 1200 E1500 D1750 D
c (front) / number mm/pce 125/2 375/2 500/2
c (back) / number mm/pce 125/2 375/2 375/2
dmm 125 30
e (without load) mm 22 42
e (with load) mm ―37
Clearance dimensions (cont.)
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Note
Lifting eyes are welded to the top of the boiler for
attaching the lifting gear. Alternatively, use the speci-
fied holes in the boiler floor.
BB
C
A
A
C
D
Fig. 5 Lifting gear attachment points:
ALifting the complete appliance
BLifting the combustion chamber module
CLifting the heat exchanger module
Note
If required, base frame D and combustion chamber
module B can be removed to facilitate handling; see
page 10.
When refitting the base support, tighten the four
screws with 70 Nm torque.
!Please note
Risk of crushing and injury.
Secure the combustion chamber module to pre-
vent it from falling.
Siting and levelling the boiler
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3.
3. 2.
F
Fig. 6
1. Insert adjusting screws F (inside the bag on the
boiler support) into the base rails from the top.
2. Undo the timbers from the boiler base.
Note
Remove transport protectors.
3. Level the boiler using the adjusting screws.
Note
We recommend installing the boiler on adjustable
anti-vibration feet C (see page 6) or anti-vibration
boiler supports D/E (see page 6).
Adjustable anti-vibration feet
Insert adjusting feet into the base rails from below.
Anti-vibration boiler supports
Any unevenness in the floor should be max. 1 mm, to
ensure the spring elements are evenly loaded.
Position the boiler supports underneath the boiler. For
this, locate them centrally underneath the base rails.
When setting the boiler down less than square on, a
boiler support can temporarily be overloaded. This can
be prevented by laying timbers (□ 35 mm) under the
front, centre and back of each boiler support.
Siting and levelling the boiler (cont.)
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D
B
A
B
C
Fig. 7
The boiler door can be rehung on the opposite side by
moving bolt A to the r.h. side.
Note
Sealing frame B should press centrally onto boiler
door gasket D when the boiler door is closed. If nec-
essary, align mounting bracket C.
Assembly after dismantling
Note
If required, combustion chamber module A can be
removed from heat exchanger module B to facilitate
handling.
To do this, loosen 4 screws in the combustion chamber
module and lower flange.
Converting the boiler door opening
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B
A
DC
2.
2.
7.
4.
3.
1.
5.
1.
6.
Fig. 8
ACombustion chamber module
BHeat exchanger module
CSilicone packing cord
DLimiting ring
!Please note
Scratches on parts that come into contact with
flue gas can lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
1. Undo nuts and screws in the boiler body and
remove the combustion chamber module.
2. Check that the silicone packing cord is seated cor-
rectly all the way round. The cord must be right
next to the limiting ring D. If required, correct the
seating of the cord and fix in place with "Gasket
Seal" (high temperature sealant, accessory).
3. Position the combustion chamber module against
the boiler body and secure at the top with
M 16 x 50 screws and nuts.
4. Insert the gasket into the joint on the water side
between the boiler sections. Connect flanges with
nuts and bolts.
5. Secure the combustion chamber module at the
bottom with M 12 x 45 screws and nuts.
6. Tighten combustion chamber module A.
Torque of top M16 screws 60 Nm.
Torque of bottom M12 screws 50 Nm.
Torque of flange screws 50 Nm.
The spacers ensure the specified gap between the
modules is maintained.
Danger
Leaks can result in a risk of poisoning
through escaping gas.
Apply the gasket carefully.
Assembly after dismantling (cont.)
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7. Position gaskets (in the pack supplied) onto both
top flanges and fit the connection lines on the
water side.
Connect flanges with nuts and bolts.
!Please note
Tighten the screws on the flanged joint to
ensure the components are not being dam-
aged and are functioning correctly.
Connections on the heating water side
H
G
F
E
D
C
B
A
Fig. 9
ABoiler return 1
for 187 and 248 kW: PN 6 DN 65
for 314 kW: PN 6 DN 80
for 408 to 635 kW: PN 6 DN 100
BDrain: R 1
CBoiler return 2
for 187 to 314 kW: PN 6 DN 50
for 408 to 635 kW: PN 6 DN 80
DFemale connection for pressure limiters: R ½
ESafety connection (safety valve)
for 187 to 314 kW: R 1¼
for 408 to 635 kW: R 1½
FBoiler water temperature sensor
GFemale connection for additional control equip-
ment: R ¾
HBoiler flow
for 187 and 248 kW: PN 6 DN 65
for 314 kW: PN 6 DN 80
for 408 to 635 kW: PN 6 DN 100
Assembly after dismantling (cont.)
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Danger
There is a risk of injury when working on pres-
surised components.
Only open the connections on the heating water
side after the boiler has been depressurised.
Note
■The boiler is only suitable for fully pumped hot water
heating systems.
■Install all pipe connections free of load and torque
stress.
1. Thoroughly flush the heating system.
2. Note
Never connect heat consumers to the safety con-
nector.
Make all necessary connections. Connecting a sin-
gle heating circuit: Connect the heating return to
boiler return 1.
Connecting two heating circuits: Connect the heat-
ing circuit with the higher temperature level to
boiler return 2.
Connect at least 15 % of the boiler heating output
to boiler return 1.
Close test ports that are not used for the installa-
tion of a measuring probe or sensor.
Connections on the flue gas side
Flue outlet and siphon
1.
3.
Fig. 10
1. Insert the boiler flue connection (Vitoset accesso-
ries) into the flue outlet as far as it will go.
Note
Connect the flue outlet to the flue pipe via the
shortest possible run, with a slight incline (min. 3º).
Avoid sharp bends.
2. Connect the flue system.
Internal 7 of the flue outlet for:
187 to 314 kW: 201 mm
408 to 635 kW: 251 mm
Flue system installation instructions
Note
Make all connections free of load and torque
stress.
We recommend providing separate support for the
flue system.
3. Fill the siphon with water and fit it to the boiler.
Connections on the heating water side (cont.)
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Boiler shell thermal insulation
2x
6x
3.
2.
4.
A A
A
1.
Fig. 11
ABlack side outwards
Note on steps 2 to 4
Connect the thermal insulation mat with an overlap.
Note
Before fitting the thermal insulation, check that the
serial no. on the type plate matches the serial no.
stamped on the boiler front panel on the reinforcing U
profile.
Fitting the thermal insulation
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Thermal insulation mat, front
1.
Fig. 12
Fitting the thermal insulation (cont.)
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Thermal insulation mats, back
1.
A
2.
B
Fig. 13
AThermal insulation mat, back
BThermal insulation mat, combustion chamber
Note
The actual thermal insulation mats delivered may differ
from those shown here.
Fitting the thermal insulation (cont.)
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Front fixing rails, retaining bracket and cross braces
M8x16
4x
A
A
B
C
B
C
M6x10
2x
1.
2.
3.
M8x16
4x
M8x16
4x
Fig. 14
1. Insert two M 8x16 screws each into the top of front
fixing rails A, then hook the rails onto the boiler
floor at the holes provided and secure with screws.
Front fixing rails A may be secured onto the lower
part of the base support using M 6x10 screws.
2. Secure both retaining brackets C onto the back of
the boiler with M 8x16 screws.
3. Position both cross braces B onto front fixing rails
A and onto retaining brackets C from the inside
and secure with M 8x16 screws.
Note
Check fixing rails A and retaining brackets C for
squareness towards cross braces B; possibly realign
retaining brackets vertically.
Fitting the thermal insulation (cont.)
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Rear and central fixing rails
M6x10
2x
M8x16
4x
M8x16
4x
M6x10
4x
E
E
D
D
1.
2.
F
Fig. 15
1. Secure both central rails D to the cross braces at
the top using M 8x16 screws and to the base sup-
port at the bottom using M 6x10 screws.
2. Secure both rear fixing rails E to the retaining
brackets.
Fitting the thermal insulation (cont.)
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90° 90°
!
!
1.
2.
3.
A
Fig. 16
1. Hook into place two side panels.
Note
Check clearance and squareness towards the fix-
ing rails.
Side panels should be parallel to each other and
be flush, level and parallel with the fixing rails at
the back and front A.
2. If necessary, align the rear fixing rails and the
cross braces so that the same clearance of side
panels to the fixing rails results at the r.h. and l.h.
side.
3. Then tighten all rail screws.
Note
Rear fixing rails may be secured below on the base
support using M 6x10 screws.
4. Unhook the two side panels again.
Fitting the thermal insulation (cont.)
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Corner rails
2.
8x
B
B
4.8
4.8
A
1.
Fig. 17
AClip (2 pce per rail; supplied with the fixings)
Information on step 1
Corner rails can be fitted on the r.h. or the l.h. side; for
this, observe the clip direction.
Front corner rails feature a decorative stripe.
Information on step 2
Hook the corner rails onto the fixing rails and secure
with screws from the inside and outside.
For a parallel seating, up to three screws B may be
used per side.
Fitting the thermal insulation (cont.)
5800301