Viessmann VITOCROSSAL 300 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 300
Type CM3
Gas condensing boiler with MatriX radiant burner
VITOCROSSAL 300
5862 417 GB 11/2014 Dispose after installation.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
!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 must only be carried out by
a registered gas fitter.
■Work on electrical equipment must only be carried
out by a qualified electrician.
Regulations
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■The Code of Practice of relevant trade associations
■all current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE [and all local standards].
aÖNORM, EN, ÖVGW-TR Gas, 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
5862 417 GB

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1. Information Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Clearance dimensions ........................................................................... 4
2. Installation sequence Siting and levelling the boiler ................................................................. 5
Fitting the thermal insulation .................................................................. 6
Connections on the heating water side .................................................. 8
Safety connections ................................................................................ 8
Making connections on the flue gas side ............................................... 9
■Exhaust gas connection ..................................................................... 9
■Condensate drain pipe ....................................................................... 9
■Neutralising system (if included) ......................................................... 9
Mounting the thermal insulation and control unit ................................... 10
Mounting the burner ............................................................................... 13
Commissioning and adjustment ............................................................. 13
Index
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Symbol Meaning
Reference to other document containing
further information
Additional information, not safety relevant
1.
Step:
The numbering corresponds to the se-
quence of work.
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. It is only designed for the heating of water that is
of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Clearance dimensions
600 450
200
Fig.1
Symbols
5862 417 GB

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!Please note
Damage to the flue outlet can result in leaks.
Never lift or move the boiler by the flue outlet.
Note
A suitable condensate drain (maximum 50 mm above
floor level) must be available in the installation room if
the boiler is installed at ground level.
±15
1.
2.
2.
Fig.2
1. Screw the adjustable feet into the base rails. The
adjustable feet are in the same bag as the type
plate.
Note
If a neutralising system is being fitted, wind out the
adjustable feet as far as possible.
2. Using the adjustable feet, position the boiler so it
rises slightly towards the back (max. 5 mm over the
boiler length). No special foundations are required.
Siting and levelling the boiler
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Note
All components required for fitting the thermal insula-
tion can be found in the box with the thermal insula-
tion.
4x
4x
2.
3.
1.
Fig.3
Fitting the thermal insulation
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4x
90°
3.
5.
1.
2.
3.
4.
Fig.4
Fitting the thermal insulation (cont.)
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C
D
A
B
E
F
H
G
Fig.5
ASafety connection (safety valve and air vent valve)
G 1¼
BBoiler flow PN 6 DN 50
CFemale connection for control equipment R ½
DFemale connection for minimum pressure switch
(low water indicator) R ½
EBoiler return 2
PN 6 DN 40
FBoiler return 1
PN 6 DN 50
GDrain and expansion vessel R 1
HCondensate drain R ½
Note
The Vitocrossal is only suitable for fully pumped hot
water heating systems.
Never install 4-way mixers, overflow valves or other
flow/return bypass devices.
Never connect heat consumers to the safety connec-
tion.
1. Thoroughly flush the heating system.
2. Connect the heating circuits.
■Connecting a single heating circuit: Connect the
heating return to boiler return F.
■Connecting 2 heating circuits: Connect the heat-
ing circuit with the higher temperature level to
boiler return E.
Connect at least 15 % of the boiler heating output
to boiler return F.
Safety connections
Safety equipment block installation instructions
1. Install the safety lines.
Safety valve minimum cross-
sections
Inlet connection
■87 kW DN 20
■115 and 142 kW DN 25
Discharge pipe
■87 kW DN 25
■115 and 142 kW DN 32
Pipe to the expansion vessel DN 20
2. Check the connections on the heating water side
for leaks.
Permiss. operating pres-
sure:
4 bar/0.4 MPa
Test pressure: 5.2 bar/0.52 MPa
Connections on the heating water side
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Low water indicator
Tests have verified that the low water indicator speci-
fied by EN 12828 is not required.
Note
Equip boilers with a safety valve that is type-tested
according to TRD 721 [or local regulations] and is
identified in accordance with the relevant system.
Making connections on the flue gas side
Exhaust gas connection
1.
3.
Fig.6
1. Connect the flue outlet to the flue via the shortest
possible run to the chimney, maintaining a slight
rise (min. 3°). Avoid sharp kinks.
2. Insert the boiler flue connection (accessories) into
the flue outlet as far as it will go.
3. Connect the flue system.
Flue pipe (internal diameter): 7 125 mm
Flue system installation instructions
4. Fit the siphon.
Condensate drain pipe
A
Fig.7
ACondensate drain
Route the condensate drain pipe with a fall below the
anti-flooding level of the flue gas collector.
The condensate drain must be accessible for inspec-
tion.
Connection external 7: 19 mm
Neutralising system (if included)
Site the neutralising system behind the boiler and con-
nect it to the condensate drain.
Connect the neutralising system to the drainage sys-
tem.
Neutralising system installation instructions
Safety connections (cont.)
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Note
Boiler water temperature sensor § is supplied in the
control unit pack.
Burner cable fA and extension together with plug lÖ
are supplied in a separate pack.
Insert the sensor and boiler water temperature sensor
§ as far as they will go into the sensor well.
!Please note
Damaged capillary tubes will result in faulty sen-
sor function.
Never kink the capillary tubes.
2.
1.
B
2.
4.
5.
3.
A
§
4x
Fig.8
ABoiler water temperature sensor §
BBurner cables fA and lÖ
For the connections to the control unit, see the
boiler control unit installation instructions
Mounting the thermal insulation and control unit
5862 417 GB