Viessmann Vitogate 300 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3B, 187 to 635 kW
Gas condensing boiler
VITOCROSSAL 300
5614 451 GB 1/2014 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 inten-
ded for qualified 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 elec-
trician.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations 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 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 sup-
ply (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 recon-
nection.
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
Safety instructions
5614 451 GB

3
Intended use....................................................................................................... 4
Preparing for installation
Clearance dimensions.......................................................................................... 5
Installation sequence
Siting and levelling the boiler................................................................................ 7
Converting the boiler door opening...................................................................... 9
Assembly when supplied in sections.................................................................... 11
Connections on the heating water side................................................................ 13
Connections on the flue gas side......................................................................... 14
■ Flue outlet and siphon....................................................................................... 14
Fitting the thermal insulation................................................................................ 16
■ Boiler shell thermal insulation........................................................................... 16
■ Thermal insulation mat, front............................................................................ 17
■ Thermal insulation mats, back.......................................................................... 18
■ Front fixing rails, retaining bracket and cross braces........................................ 19
■ Rear and central fixing rails.............................................................................. 21
■ Corner rails....................................................................................................... 23
■ Side panels and burner cables......................................................................... 24
■ Front panels...................................................................................................... 25
■ Boiler door......................................................................................................... 26
■ Back panels, covers, cap and boiler water temperature sensor....................... 29
■ Top panels and reinforcement struts ............................................................... 30
■ Preparing the control unit installation................................................................ 31
■ Type plate......................................................................................................... 33
Connecting the neutralising system..................................................................... 34
Making the safety connections ............................................................................ 35
Mounting the burner............................................................................................. 35
Fuels..................................................................................................................... 36
Fitting the sight glass............................................................................................ 36
Adjusting the burner............................................................................................. 36
Commissioning and adjustment........................................................................... 37
Index
5614 451 GB

4
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Intended use
5614 451 GB

5
D
200
a
b
500
500 (400)
500 (50)
(400)
A B
C E
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
D
c
d
e
d
c
e
E
Clearance dimensions
5614 451 GB

6
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.)
5614 451 GB

7
Note
Lifting eyes are welded to the top of the
boiler for attaching the lifting gear. Alter-
natively, use the specified holes in the
boiler floor.
BB
C
A
A
C
D
Lifting gear attachment points:
ALifting the complete appliance
BLifting the combustion chamber
module
CLifting the heat exchanger module
Siting and levelling the boiler
5614 451 GB

8
Note
Base support D may be removed by
undoing four screws to make handling
easier.
When refitting the base support, tighten
the four screws with 70 Nm torque.
3.
3. 2.
F
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.
Siting and levelling the boiler (cont.)
5614 451 GB

9
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 5) or anti-vibration boiler sup-
ports D/E (see page 5).
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 ele-
ments 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 tempo-
rarily be overloaded. This can be pre-
vented by laying timbers (□ 35 mm)
under the front, centre and back of each
boiler support.
Converting the boiler door opening
D
B
A
B
C
Siting and levelling the boiler (cont.)
5614 451 GB

10
Note
When converting the boiler door hinges
by moving hinge pins A to the r.h. side,
ensure that gasket frame B is pressed
centrally onto boiler door gasket D
when the boiler door is closed (see
detail); if required, align mounting brack-
ets C.
Converting the boiler door opening (cont.)
5614 451 GB

11
2.
3.
5.
1.
6.
9.
1.
4.
Assembly when supplied in sections
5614 451 GB

12
!Please note
Scratches on parts that come into
contact with flue gas can lead to
corrosion.
Never put tools or other objects
into the combustion chamber.
1. Undo nuts and screws of the boiler
body and remove the combustion
chamber module.
2. Attach adhesive tape to the joints on
the inside of the combustion chamber
to prevent sealant adhering to these
areas. On the heat exchanger mod-
ule, affix adhesive tape approx. 8 to
10 mm behind the front edge.
3. Evenly and generously apply the
sealant supplied into the annular
groove on the combustion chamber
module.
4. Attach the combustion chamber
module to the boiler body by securing
with M 16 x 50 screws and nuts at the
top (torque 60 Nm); the spacers
ensure the specified gap between the
modules is maintained.
5. Insert the gasket (in the pack sup-
plied) into the joint on the water side
between the boiler sections, and con-
nect the flanges with nuts and bolts.
6. Secure the combustion chamber
module at the bottom with M 12 x 45
screws and nuts (torque 50 Nm); the
spacers ensure the specified gap
between the modules is maintained.
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.
Danger
Leaks can result in a risk of
poisoning through escaping
gas.
Apply the gasket carefully.
8. Remove the adhesive tape when the
sealant has dried sufficiently (approx.
four hours).
9. Position gaskets (in the pack sup-
plied) 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
damaged and are functioning
correctly.
Assembly when supplied in sections (cont.)
5614 451 GB

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H
G
F
E
D
C
B
A
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 lim-
iters: 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 equipment: 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
Connections on the heating water side
5614 451 GB

14
Danger
There is a risk of injury when
working on pressurised compo-
nents.
Only open the connections on the
heating water side after the boiler
has been depressurised.
Note
■ The boiler is only suitable for fully pum-
ped hot water heating systems.
■ Install all pipe connections free of load
and torque stress.
1. Thoroughly flush the heating sys-
tem.
2. Note
Never connect heat consumers to the
safety connector.
Make all necessary connections.
Connecting a single heating circuit:
Connect the heating return to
boiler return 1.
Connecting two heating circuits: Con-
nect the heating 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 installation of a probe or sensor.
Connections on the flue gas side
Flue outlet and siphon
1.
3.
Connections on the heating water side (cont.)
5614 451 GB

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1. Insert the boiler flue connection
(Vitoset accessories) 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. 3°). 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 flue gas side (cont.)
5614 451 GB

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Boiler shell thermal insulation
2x
6x
3.
2.
4.
A A
A
1.
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 number on the type
plate matches the serial number stam-
ped on the boiler front panel.
Fitting the thermal insulation
5614 451 GB

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Thermal insulation mat, front
1.
Fitting the thermal insulation (cont.)
5614 451 GB

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Thermal insulation mats, back
1.
A
2.
B
AThermal insulation mat, back
BCombustion chamber thermal insu-
lation mat
Note
The actual thermal insulation mats deliv-
ered may differ from those shown here.
Fitting the thermal insulation (cont.)
5614 451 GB

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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
Fitting the thermal insulation (cont.)
5614 451 GB

20
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 sup-
port 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 retain-
ing brackets vertically.
Fitting the thermal insulation (cont.)
5614 451 GB