Viessmann VITOCROSSAL 300 User manual

VITOCROSSAL 300
Installation instructions
for heating engineers
Vitocrossal300
TypeCT3, 187 to 635kW
Gas fired condensing boiler
5862170 GB6/2003

2
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety regulations
Installation, initial start−up, inspection,
maintenance and repairs must only
be carried out by a competent person
(heating engineer/installation
contractor).
Observe all current safety regulations
as defined by DIN, EN, DVGW, TRGI,
TRF and VDE or locally applicable
standards.
See also the safety instructions sheet
in the Vitotec technical documentation
folder.
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut−off valve
and safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations to
TRGI or TRF and all local regulations.
Please observe all commissioning
work specified for gas systems.
¨Safety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes information
which must be observed to
prevent material losses.
5862170 GB

3
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning
Clearances 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler handling, positioning and adjustment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly when supplied in sections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections
Flue gas connections 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating water (primary) connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety connection and testing for leaks 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of the neutralising system 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal insulation
Installation of thermal insulation 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HPreparing the control unit installation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HTop panel installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HInstallation of back panel, boiler door and cable channel 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner
Burner installation 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuels 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion chamber sight glass installation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner settings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Initial start−up 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862170 GB

4
Clearances
Note
You can relocate the hinge bolts so that the door can open to the l.h. side.
ABoiler
BBurner
Dimensions in brackets are minimum clearances
Rated output kW 187 248 314 408 508 635
Dimensiona mm 930 1000 1100 1500 1500 1500
5862170 GB
200
a
500
500 (400)
500 (50)
(400)
B
A
Finished
burner length

5
Boiler handling, positioning and adjustment
Lifting eyes for securing lifting tackle
have been welded to the top of the
boiler.
1. Remove the transport timbers
from the bottom of the boiler.
2. Insert adjustable feet (inside the
bag on the bottom of the boiler)
from the top into the foot rails.
3. Level the boiler using the
adjustable feet.
Please note
We recommend the installation of
the boiler on anti−vibration
supports.
5862170 GB

6
Assembly when supplied in sections
5862170 GB
1.
4.
9.
2.
4.
3.
5.
6. 1.

7
Assembly when supplied in sections (cont.)
¨Do not put tools or other objects
into the combustion chamber.
1. Release the turnbuckles and
screws M12 on the bottom of the
boiler body, pull the boiler front
section out of the turnbuckles and
remove it.
2. Secure adhesive tape to all joints
on the inside of the combustion
chamber to prevent sealant
adhering to these areas. Affix
adhesive tape on the rear boiler
section approx. 8 to 10mm behind
the front edge.
3. Evenly and generously apply the
sealant supplied into the annular
groove on the front section of the
combustion chamber.
4. Position the front section of the
combustion chamber on the
boiler, and secure with screws
M16×150 and nuts on both
turnbuckles.
5. Insert the gasket (part of the pack
supplied) in contact with the water
side between the boiler sections
and connect the relevant flanges
with nuts and bolts.
6. Secure the front section of the
combustion chamber at the lower
end with screws M12×45 and nuts.
7. Remove all protruding sealant
inside the combustion chamber.
Check whether sufficient sealant
has been applied all around to
prevent any gaps appearing in the
combustion chamber.
8. Remove the adhesive tape when
the sealant has sufficiently dried
(approx. four hours).
9. Position gaskets (in the pack
supplied) onto both top flanges
and fit the pipework to the water
side.
Connect flanges with nuts and
bolts.
Flue gas connections
Flue gas system installation
instructions
Internal ∅of the flue outlet at:
187 to314kW 201mm. . . . . . . . . . . . . . . . . . . . . . . . . . .
408 and 635kW 251mm. . . . . . . . . . . . . . . . . . . . . . . .
5862170 GB

8
Heating water (primary) connections
DB Female connection for maximum pressure limiter R½". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E Drain R1". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOA Condensate drain R½". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KR1 Boiler return1/KV boiler 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. . . .
KR2 Boiler return2 for 187 to314kW PN6DN50. . . .
for 408 to 635kW PN6DN80. .
KTS Boiler temperature sensor
RG Female connection for additional control units R¾"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SA Safety connection (safety valve) for 187 and 248kW PN6DN32. . . .
for 314 to 635kW PN6DN50. .
WB Female connection for water level limiter R2". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862170 GB
RG
KV
DB
SA
KTS
KR2
E
KR1
KOA
WB

9
Heating water (primary) connections (cont.)
¨Safety instructions
Only open the heating water connections after the boiler has been depressurised.
Note
This boiler is only suitable for heating systems with pumped domestic hot water.
Install all pipe runs free of load and torque stresses.
1. Thoroughly flush the heating
system.
2. Please note
Do not connect consumers to the
connector of the safety
connection.
Make all necessary connections.
Heating circuit connection:
Connect the central heating return
to boiler returnKR1.
Connecting two heating circuits:
Connect the heating circuit with
the higher temperature level to
boiler returnKR2.
Connect at least 15% of the boiler
output to boiler returnKR1.
Close off test ports which are not
used for the installation of a probe
or sensor.
5862170 GB

10
Safety connection and testing for leaks
¨Safety instructions
Install all pipe runs free of load and torque stresses.
Equip boilers with a safety valve which is type−tested and meets the
requirements of TRD721, and which must be marked for each system version.
1. Create the safety connection.
2. Check the primary connections for
possible leaks.
Permissible operating
pressure 4bar
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test pressure 5.2bar. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special version 408 to 635kW
(see type plate):
Permissible operating
pressure 5.5bar
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler test pressure 7.15bar. . . . . . . . . . . .
¨Only fill the boiler with water
which complies with the water
quality requirements
(see service instructions).
5862170 GB

11
Connection of the neutralising system
Neutralising system
installation and service
instructions
1. Locate the neutralising system
either behind or next to the boiler.
2. Trim the plastic hose supplied to
the required dimension, and
connect it as a U−bend (or with a
siphon) to the condensate drain
and the neutralising system.
¨Safety instruction
Always connect the drain with a
U−bend or siphon to prevent flue
gas from escaping.
3. Connect the neutralising system to
the dewatering system.
5862170 GB

12
Installation of thermal insulation
Please note
Do not put tools or other objects into the combustion chamber.
1. Fit the boiler door.
2. Secure three fixing brackets (long)
to the threaded studs on the front
of the boiler body.
3. Secure three fixing brackets
(short) to the threaded studs on
the rear of the boiler body.
4. Push the thermal insulation mat
external casing through between
the boiler body and the connection
pipe.
5. Insert three spacer studs M8×105
into the threaded holes at the top.
6. Insert four spacer studs M8×87
respectively into the threaded holes
in the front and back of the boiler.
5862170 GB
4.
3.
6.
6.
2.
1.
5.

13
Installation of thermal insulation (cont.)
7. Secure the thermal insulation mat
external casing at the front and
secure with spring hooks.
8. Push on the thermal insulation
mat at the bottom onto the front
and back and secure with spring
hooks to the thermal insulation
mat external casing.
9. Push the thermal insulation mat
onto the top of the rear and front
of the boiler.
5862170 GB
7.
8.
9.
9.
7.
8.

14
Installation of thermal insulation (cont.)
10. Secure the front panels with
screws M8×10 to the fixing
brackets.
11. Secure the back panels with
screws M8×10 to the fixing
brackets.
5862170 GB
10.
11.

15
Installation of thermal insulation (cont.)
12. Fit the short side panel to the
side where the control unit is to
be installed.
13. Secure both panels with screws
M8×40 to the centre front and
bottom back panels.
14. Secure the bottom of the front
panels with screws M8×40 to
the side panels.
5862170 GB
13.
13.
14.
12.

16
Installation of thermal insulation (cont.)
Preparing the control unit installation
1. Secure the bottom of the
mounting panel with self−tapping
screws B3.9×9.5 on the side
panel.
2. Secure the mounting panel with
self−tapping screws B3.9×9.5 on
the back of the mounting panel
(closed side oriented towards the
boiler door).
3. Hook the rear of the control unit
into the hooks on the rear wall of
the panel.
4. Pull burner cablesfA and lÖ
forward through the clean−out
aperture (position surplus cable
lengths above the side panel).
5. Secure the back of the control unit
with self−tapping screws B3.9×30
on the back of the mounting panel.
5862170 GB
1.
5.
3.
4.
2.

17
Installation of thermal insulation (cont.)
6. Push the boiler temperature sensor
lead§(supplied with the control
unit) through the aperture in the
side panel, and push the back of
the control unit forward through
the opening (position excess leads
above the side panel).
7. Please note
Do not kink the capillary tubes,
otherwise the sensor function may
be compromised.
Push the capillary tubes through
the side panel aperture (position
excess lengths of leads above the
side panel).
¨Safety instructions
Set the high limit safety cut−out to
a maximum of 110ºC.
Installation and service
instructions, boiler
control unit
5862170 GB
7.
6.

18
Installation of thermal insulation (cont.)
8. Secure the side panel with the
control unit above the short side
panel using screws M8×40.
9. Route the boiler temperature
sensor and capillary tubes to the
sensor well, and push in as far as
possible.
10. Route the burner cables to the
front.
5862170 GB
10.
9.
8.

19
Installation of thermal insulation (cont.)
Top panel installation
5862170 GB
8.
1.
5. 2.
7.
6.
3.
5.
4.

20
Installation of thermal insulation (cont.)
1. Fit the finned panels on the l.h.
top, centre and l.h. bottom
together using oval screws
M6×10.
2. Hook the l.h. finned panels into the
threads of the spacer studs and
locate them in the side panel tab.
3. Fit the finned panels on the r.h.
top, centre and bottom together
using oval screws M6×10.
4. Hook the r.h. finned panels into the
threads of the spacer studs and
locate them in the side panel tab.
5. Secure the finned panels with M8
nuts and washers on the spacer
studs, and secure together with
self−tapping screws B3.9×9.5.
6. Secure the bottom of the finned
panels with self−tapping screws
B3.9×9.5.
7. Route burner cablesfA and lÖ
through the strain relief aperture
in the top of the front panel.
8. Fit the front panel onto the top of
the finned panels, and secure with
screws M8×10.
9. Thermally insulate the connecting
pipe to the boiler flow (horizontal
pipe at the top of the boiler) using
suitable material.
5862170 GB