Viessmann VITOCROSSAL 300 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 300
Type CR3B, 787 to 1400 kW
Gas condensing boiler
VITOCROSSAL 300
5836848 GB 6/2019 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 Clearances and dimensions .................................................................. 6
■Anti-vibration boiler support ................................................................ 7
Thermal insulation sections ................................................................... 8
■Thermal insulation, pack 1 .................................................................. 8
■Thermal insulation, pack 2 .................................................................. 9
■Thermal insulation, pack 3 .................................................................. 10
■Fixings ................................................................................................ 11
3. Installation sequence Siting the boiler ...................................................................................... 12
■Installation without anti-vibration boiler supports ................................ 12
■Installation with anti-vibration boiler supports ..................................... 12
Assembling the boiler ............................................................................ 13
■Fitting the supplied foot supports to the heat exchanger module ....... 14
■Levelling the combustion chamber and heat exchanger modules
horizontally ......................................................................................... 15
Connections on the heating water side .................................................. 16
Fitting the thermal insulation .................................................................. 17
■Boiler body thermal insulation ............................................................ 17
■Rails, top and bottom .......................................................................... 18
■Reinforcing struts and tie-bars ............................................................ 19
■Heat exchanger support panel and thermal insulation mat ................ 20
■Side panels, burner cables and boiler water temperature sensor ...... 21
■Front corner rails ................................................................................ 22
■Front panels ........................................................................................ 23
■Back panels ........................................................................................ 24
■Top panels .......................................................................................... 25
Control unit installation .......................................................................... 26
■Preparing the control unit installation ................................................. 26
■Fitting and connecting the control unit ................................................ 27
Making the safety connections .............................................................. 27
■Safety valve ........................................................................................ 27
Mounting the siphon .............................................................................. 28
Connecting the neutralising system ....................................................... 28
Connections on the flue gas side ........................................................... 29
■Fitting the flue gas temperature sensor .............................................. 29
Mounting the burner ............................................................................... 29
Combustion chamber sight glass ........................................................... 30
■Mounting the combustion chamber sight glass .................................. 30
■Closing off the sight glass aperture on burners without ventilation
connection .......................................................................................... 31
Pressure switch ..................................................................................... 32
■Pressure switch .................................................................................. 32
Fuels ...................................................................................................... 32
Closing the boiler door ........................................................................... 32
4. Commissioning and
adjustment
Adjusting the burner ............................................................................... 34
Commissioning ...................................................................................... 34
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
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.
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.
Disposal of packaging
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Vitocrossal 300, type CR3B
■Fuel: Natural gas E, natural gas LL and LPG
■Rated heating output 787 kW and 1400 kW
■Permissible operating pressure 6 bar (0.6 MPa)
System examples
Available system examples: See www.viessmann-
schemes.com.
Product information
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Note
The stated clearances are recommended clearances.
Minimum clearances are indicated in brackets.
1600
(300)
200 (100)
b
400
a
ABc
C
Fig. 1
ABoiler
BBurner
CAnti-vibration boiler supports
Note
In the delivered condition, the burner door opens to the
right. The hinge pins of the burner door can be reposi-
tioned so that the burner door opens to the left.
Dimension a b c
Clearance
in mm
Minimum
clear-
ance
Recom-
mended
clear-
ance
Minimum
clear-
ance
Recom-
mended
clear-
ance
Right-hand boiler: Burner door opens to the right.
And
Left-hand boiler: Burner door opens to the left.
50 500 c + 100 c + 200 Installed burner
length
Right and left-hand boilers: Burner door opens to
the right.
c + 100 c + 200 50 500
Clearances and dimensions
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Anti-vibration boiler support
c
e
d
Fig. 2
Rated heating output kW 787 978 1100 1400
Permissible load kg 4668 6004
c Boiler front
■Length
■Quantity
mm
pce
500
2
667
2
Boiler back
■Length
■Quantity
667
2
883
2
d mm 100
e■Spring element, unloaded
■Spring element, loaded
mm 42
38-39
Clearances and dimensions (cont.)
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The thermal insulation and casing are supplied in 3
packs. The following is a list of the components in the
individual packs.
Note
The position numbers correspond to the "Casing
assembly" parts list in the service instructions.
Thermal insulation, pack 1
0022
0021
0035
0034
0015
0015
0039
0009
0033
0032
0009
0042
0015
0015
0016
0014
0013
Fig. 3
Pos. Designation
0009 Reinforcing strut
0013 Side panel, front right
0014 Side panel, control unit
0015 Side panel, centre
0021 Front panel, top
0022 Front panel, bottom
Pos. Designation
0032 Mounting bracket rear panel
0033 Mounting bracket
0034 Mounting bracket fascia
0035 Trunking retainer
0039 Thermal insulation jacket, front
Thermal insulation sections
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Thermal insulation, pack 2
0024
0019
0015
0017
0024
0025
0040
0023
0020
0018
Fig. 4
Pos. Designation
0015 Side panel, centre
0017 Side panel, back left
0018 Side panel, front left
0019 Corner rail
0020 Corner rail, right
Pos. Designation
0023 Back panel, bottom
0024 Cover panel
0025 Back panel, top
0040 Thermal insulation jacket, centre
Thermal insulation sections (cont.)
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Thermal insulation, pack 3
0006
0031
0027
0010
0010
0001
0002
0010
0028
0010
0043
0036
0026
0041
0012
0008
0037
0029
0005
0007
0004
0003
0030
0038
Fig. 5
Pos. Designation
0001 Rail, top front right
0002 Rail, top back right
0003 Rail, top front left
0004 Rail, top back left
0005 Rail, bottom front right
0006 Rail, bottom back right
0007 Rail, bottom front left
0008 Rail, bottom back left
0010 Tie-bar
0012 Heat exchanger support panel
0026 Top panel, centre back
Pos. Designation
0027 Top panel, back
0028 Top panel, centre
0029 Top panel, left
0030 Top panel, centre, connector
0031 Top panel, right
0036 Cable channel, lower section
0037 Cable channel, upper section (only boilers
1100/1400 kW)
0038 Cable channel, upper section
0043 For fixings, see the following table
Thermal insulation sections (cont.)
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Fixings
The following is a list of the components required for
fastening the individual items. For easier identification,
the components have been assigned position num-
bers. The position numbers in circles are referenced in
the descriptions of the steps to be carried out.
Pos. Designation Quantity Component
1Spring hook for thermal insulation mats 16
2Self-tapping screw 4.8 x 9.5 65
3Self-tapping screw 4.8 x 19 5
4Oval head screw M6 x 16 32
5Spring clip 18
Thermal insulation sections (cont.)
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Installation without anti-vibration boiler supports
2.
1.
Fig. 6
1. Insert the adjusting screws into the base rails.
Position a plate, e.g. a flat steel strip, underneath
the adjusting screws to distribute the load evenly.
2. Level the boiler horizontally. No special founda-
tions are required.
Installation with anti-vibration boiler supports
To ensure that the spring elements are uniformly loa-
ded, ensure that the installation surface on site is level,
with max. 1 mm in the floor.
1. Lift the combustion chamber module by the lifting
eyes.
2. Arrange the vibration-absorbing boiler supports
centrally under the base rails.
3. A short-term overloading of a boiler support can
arise when setting the boiler down, due to it tilting.
In order to avoid this overloading, distribute square
timbers (□ 35 mm) evenly under the base rails
between the boiler supports as an installation aid.
4. Position the combustion chamber module on vibra-
tion-absorbing boiler supports.
5. Remove the square timbers.
Siting the boiler
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C
B
A
2.
C
A
B
E
D
D
D
D
3.
8x
150 Nm
4x
60 Nm
4.
M 16
Fig. 7
ACombustion chamber module
BHeat exchanger module
CGaskets (part of the standard delivery)
DGuide bolts for combustion chamber module with
M 16 nuts and dished washers (supplied)
EPacking cord
1. Lift the heat exchanger module by the lifting eye.
5. After installation, use a torch to check from the
inside (combustion chamber) that packing cord E
is positioned correctly.
!Please note
Scratches inside the combustion chamber or on
components that come into contact with flue gas
can lead to corrosion damage.
Never place tools or other objects inside the
combustion chamber.
Assembling the boiler
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Fitting the supplied foot supports to the heat exchanger module
2.
1.
2x
3.
Fig. 8
Assembling the boiler (cont.)
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Levelling the combustion chamber and heat exchanger modules horizontally
6x
Fig. 9
Assembling the boiler (cont.)
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Note
The boiler is only suitable for fully pumped hot water
heating systems.
A B CD E F
G
H
Fig. 10
ABoiler return 2: PN 6 DN 100
BBoiler return 1
787 and 978 kW: PN 6 DN 100
1100 and 1400 kW: PN 6 DN 125
CSafety connection (safety valve): R 2
DFemale connection for pressure limiter: R ½
EBoiler flow
787 and 978 kW: PN 6 DN 100
1100 and 1400 kW: PN 6 DN 125
FFemale connection for control equipment: R ½
GDrain outlet: R 1¼
HCondensate drain: R ½
1. Thoroughly flush the heating system.
Connections on the heating water side
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2. Connect the hydraulic lines.
System with 1 heating circuit
■Connect the heating return to boiler return 1 B.
System with 2 heating circuits
■Connect the heating circuit with the higher tem-
perature level to boiler return 2 A.
■Connect at least 15 % of the boiler heating out-
put to boiler return 1 B.
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Make all pipe connections free of load and
torque stress.
3. Seal any unused connections.
Note
Do not connect any heat consumers to the connec-
tor of safety connection C.
4. Check the hydraulic connections for leaks.
!Please note
Unsuitable water quality can damage the
boiler body.
Only fill the boiler with water that complies
with the "Water quality requirements" to VDI
2035. See service instructions.
5. Thermally insulate the hydraulic lines.
Fitting the thermal insulation
Boiler body thermal insulation
2.
4.
1.
3.
5.
12x
A
B
Fig. 11
ABlack side outwards
2. Remove bag B containing the type plates and
keep safe. This will be required later.
Note
In the delivered condition, 2 type plates are availa-
ble.
Before fitting the thermal insulation: Check that the
serial number on the type plate matches the serial
number stamped on the boiler front panel.
5. Connect the thermal insulation mats with tension
springs 1 so that they overlap.
Connections on the heating water side (cont.)
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Rails, top and bottom
1.
2.
3.
M6
A
B
Fig. 12
ARail, front (short)
BRail, back (long)
1. Insert M 6 screws 4 halfway into the base and
head rails.
2. Hang the rails onto the screws at the top and bot-
tom.
3. Tighten the screws.
Note
Ensure the bottom front rails are flush with the boiler
floor, then align the back rails accordingly.
For a detailed description of the rail alignment, see
chapters "Reinforcing struts and tie-bars" and "Heat
exchanger support panel and heat exchanger thermal
insulation mat".
Fitting the thermal insulation (cont.)
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Reinforcing struts and tie-bars
1.
C
C
2.
A
A B C
Fig. 13
1. Secure reinforcing strut A with self-tapping screw
4.8 x 9.5 2 to upper rails B.
2. Secure 4 tie-bars C with self-tapping screw 4.8 x
9.5 2 to the upper rails.
3. If necessary, release top rails B again and realign.
Check the distance between the reinforcing struts
and the boiler floor and ensure they are parallel.
4. Check whether the tie-bars and rails form a right
angle.
5. If necessary realign the bottom rails.
Fitting the thermal insulation (cont.)
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Heat exchanger support panel and thermal insulation mat
B
3.
2.
C
1. M6 x 16
4.
4,8 x 9,5
A
Fig. 14
AHeat exchanger support panel
BHeat exchanger thermal insulation mat (black side
outwards)
CSupport bracket, screws 4 (for 1100 and
1400 kW)
3. Align and secure the heat exchanger support panel
between the upper rails. The support panel fixes
the rails in place horizontally.
5. Secure the thermal insulation mat with spring
hooks 1.
Note
The heat exchanger support panel may be different
subject to output size.
Fitting the thermal insulation (cont.)
5836848