Viessmann VITOCROSSAL 300 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 300
Type CR3 and CR37
Gas fired condensing boiler
Rated output 787 and 978 kW
VITOCROSSAL 300
5862 299 GB 11/2009 Dispose after installation.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas appliances must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a mains isolator.
■ Safeguard the system against unau-
thorised reconnection.
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
Safety instructions
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Preparing for installation................................................................................... 4
Installation sequence
Boiler positioning and levelling............................................................................. 6
■Installation with anti-vibration boiler supports................................................... 6
■Installation without anti-vibration boiler supports.............................................. 6
Assembly when supplied in sections.................................................................... 7
Fitting the feet to the heat exchanger module...................................................... 9
Flue gas connection............................................................................................. 9
Fitting the thermal insulation................................................................................ 10
■ Boiler body thermal insulation........................................................................... 10
■ Front thermal insulation.................................................................................... 11
■ Front rails.......................................................................................................... 11
■ Back rails.......................................................................................................... 12
■ Centre rails........................................................................................................ 13
■ Routing burner cables....................................................................................... 14
■ Side panels and back rails................................................................................ 14
■ Rear thermal insulation..................................................................................... 15
■ Rear panels....................................................................................................... 16
■ Front panels...................................................................................................... 17
■ Preparing the control unit installation................................................................ 18
■ Fitting the top panels......................................................................................... 20
Connecting the heating water side....................................................................... 21
Making the safety connections ............................................................................ 22
Stench trap installation......................................................................................... 23
Connection of the neutralising system................................................................. 24
Burner installation................................................................................................. 24
Fuels..................................................................................................................... 24
Installing the combustion chamber sight glass..................................................... 25
Adjust burner........................................................................................................ 25
Commissioning and adjustment........................................................................... 25
Index
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Clearance dimensions
Note
You can reposition the hinge bolts so
that the door opens to the left.
a
(300)
200 (100)
500 (50)
400
500 (50)
ABb
C
ABoiler
BBurner
CAnti-vibration boiler supports
Dimensions in brackets are minimum
clearances.
Preparing for installation
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c
e
d
C
Rated output kW 787 978
amm 1500 1500
bmm Observe the burner
length
Anti-vibration boiler supports
Permissible load kg 3000
c (front) / number mm/pce 750/2
c (back) / number mm/pce 750/2
dmm 30
e (without stress) mm 42
e (stressed) mm 37
Preparing for installation (cont.)
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1.
2.
Installation with anti-vibration boiler supports
Ensure the boiler foundation is level.
Position the boiler onto the anti-vibration
boiler supports. Continue on page 7
or 9.
Installation without anti-vibration boiler supports
1. Insert the adjustable screws into the
bottom rails. Position a plate, e.g. a
flat steel strip, underneath each
adjusting screw to evenly distribute
the weight.
2. Level the boiler. Special foundations
are not required.
Boiler positioning and levelling
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D
D
C
3.
1.
5.
4.
2.
4.
B
A
C
B
A
1.
5.
6.
3.
AHeat exchanger module
BCombustion chamber module
CSealant (in the pack supplied)
DGaskets (in the pack supplied)
Assembly when supplied in sections
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!Please note
Scratches on parts that are in
contact with flue gas can lead to
corrosion.
Never put tools or other objects
into the combustion chamber.
1. Apply sufficient (2-3 tubes) sealing
material (part of the standard deliv-
ery) evenly to the annular groove of
the combustion chamber and heat
exchanger modules.
2. Position the heat exchanger module
on the combustion chamber module.
Note
Use the lifting eye to lift the heat
exchanger module.
3. Insert gaskets (in the pack supplied)
between the upper and lower flanges
and tighten screws and nuts diago-
nally.
4. Fit and tighten the M16 nuts by
hand.
5. Check that there is sufficient sealant
all around the sealing face of the
combustion chamber.
Close any gaps between the com-
bustion chamber module and the
heat exchanger module with seal-
ant.
Danger
Solvent vapours from the
sealant can cause irritation of
the respiratory system.
Ensure adequate ventilation
in the combustion chamber or
wear breathing equipment.
Note
Allow 4 hours for the sealant to dry
before commissioning.
6. Remove excess sealant (out of the
combustion chamber) from the heat
exchanger module.
Assembly when supplied in sections (cont.)
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2.
3.
1.
1. Wind the anti-vibration feet in as far
as possible.
2. Secure the feet with two screws each
to the l.h. and r.h. side of the heat
exchanger using the top holes.
3. Wind out the feet until the heat
exchanger module is sufficiently sup-
ported.
Flue gas connection
Ø 10 mm
D
2-3 x D
A
Flue gas system installation
instructions
1. Connect the flue outlet via the short-
est possible run to the chimney stack,
maintaining a slight incline.
Avoid sharp bends.
Flue internal 7: 301 mm
2. Create a resealable test port A.
3. Seal the flue (all flue connections
must be pressure-tight).
Fitting the feet to the heat exchanger module
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Boiler body thermal insulation
Note
Before fitting the thermal insulation,
check the serial number on the type plate
and compare it with the serial number
stamped on the front of the boiler.
If the boiler is supplied in sections,two
type plates will be included.
3.
1.
2.
5.
4.
Fitting the thermal insulation
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Front thermal insulation
2.
1.
Front rails
1.
1.
1.
2.
2.
2.
Fitting the thermal insulation (cont.)
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Back rails
Note
Do not tighten the wing screws yet.
1.
2.
2x
2x
Fitting the thermal insulation (cont.)
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Centre rails
3.
1.
6.
5.
1.
5.
2.
4.
1. Secure the wing screws to the top
and bottom boiler rails.
2. Hook the centre rail into the wing
screws and loosely tighten by hand.
3. Hook the bottom of the side panels on
both sides into the boiler.
4. If necessary, align the rails so that the
gap between both side panels runs
parallel.
5. Secure the centre rails.
6. Remove the bottom of the side pan-
els from both sides of the boiler.
Fitting the thermal insulation (cont.)
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Routing burner cables
xx
xx
lÖ
fA
2.
1.
3.
Side panels and back rails
3.
1.
2.
Note
Secure the rails after alignment.
Fitting the thermal insulation (cont.)
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Rear thermal insulation
2.
1.
Fitting the thermal insulation (cont.)
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Rear panels
2.
3.
1.
3.
Fitting the thermal insulation (cont.)
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Front panels
1.
2.
Fitting the thermal insulation (cont.)
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Preparing the control unit installation
B 3.9 x 30
A
2.
1.
3.
ABoiler coding card (part of boiler
accessories)
Note
Boiler water temperature sensor § is
included with the control unit. Insert the
probe and the boiler water temperature
sensor as far as possible into the sensor
well.
!Please note
Damaged capillary tubes result in
incorrect sensor functions.
Never kink the capillary tubes.
Fitting the thermal insulation (cont.)
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§
A
4.
7.
6.
4.
AStrain relief
Pull all external cables through the aper-
tures in the back and front walls into the
control unit wiring chamber.
Installation instructions, boiler
control unit
Note
Set the high limit safety cut-out to a max-
imum of 110 ºC.
Installation and service instruc-
tions; boiler control unit
Fitting the thermal insulation (cont.)
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Fitting the top panels
5.
2.
4. 1.
3.
4.
B 3.9 x 30
Note
Affix the type plate in an accessible place
to the front of the side panel.
Only when supplied in sections:
Remove the bottom section (with bar-
code) from the smaller type plate of the
heat exchanger module and affix it to the
section provided in the centre of the
larger type plate for the whole boiler.
Fitting the thermal insulation (cont.)
5862 299 GB