Viessmann VITOCROSSAL 300 Installation Instructions Manual
Gas fired condensing boiler
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Also See for VITOCROSSAL 300:
- Service instructions manual (164 pages) ,
- Service instructions for contractors (148 pages) ,
- Service manual (108 pages)
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Summary of Contents for Viessmann VITOCROSSAL 300
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Page 1: Installation Instructions
Installation instructions for heating engineers Vitocrossal 300 Type CT3, 187 to 635 kW Gas fired condensing boiler VITOCROSSAL 300 5862 170 GB 6/2003... -
Page 2: Safety Instructions
Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety regulations Close the main gas shut−off valve Installation, initial start−up, inspection, and safeguard against unauthorised maintenance and repairs must only reopening. be carried out by a competent person (heating engineer/installation Work on gas equipment contractor). -
Page 3: Table Of Contents
Index Page General information Safety instructions ........................Positioning Clearances . -
Page 4: Clearances
Clearances Note You can relocate the hinge bolts so that the door can open to the l.h. side. 500 (400) 500 (50) (400) A Boiler B Burner Dimensions in brackets are minimum clearances Rated output Dimension a 1 000 1 100 1 500 1 500 1 500... -
Page 5: Boiler Handling, Positioning And Adjustment
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. -
Page 6: Assembly When Supplied In Sections
Assembly when supplied in sections... -
Page 7: Flue Gas Connections
Assembly when supplied in sections (cont.) ¨ Do not put tools or other objects 5. Insert the gasket (part of the pack into the combustion chamber. supplied) in contact with the water side between the boiler sections 1. Release the turnbuckles and and connect the relevant flanges screws M 12 on the bottom of the with nuts and bolts. -
Page 8: Heating Water (Primary) Connections
Heating water (primary) connections Female connection for maximum pressure limiter R ½" ........Drain R 1"... - Page 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.
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Page 10: Safety Connection And Testing For Leaks
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. ¨... -
Page 11: Connection Of The Neutralising System
Connection of the neutralising system Neutralising system 3. Connect the neutralising system to installation and service the dewatering system. 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. -
Page 12: Installation Of Thermal Insulation
Installation of thermal insulation Please note Do not put tools or other objects into the combustion chamber. 1. Fit the boiler door. 4. Push the thermal insulation mat external casing through between 2. Secure three fixing brackets (long) the boiler body and the connection to the threaded studs on the front pipe. - Page 13 Installation of thermal insulation (cont.) 7. Secure the thermal insulation mat 9. Push the thermal insulation mat external casing at the front and onto the top of the rear and front secure with spring hooks. of the boiler. 8. Push on the thermal insulation mat at the bottom onto the front and back and secure with spring hooks to the thermal insulation...
- Page 14 Installation of thermal insulation (cont.) 10. Secure the front panels with 11. Secure the back panels with screws M 8 × 10 to the fixing screws M 8 × 10 to the fixing brackets. brackets.
- Page 15 Installation of thermal insulation (cont.) 12. Fit the short side panel to the 14. Secure the bottom of the front side where the control unit is to panels with screws M 8 × 40 to be installed. the side panels. 13.
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Page 16: Preparing The Control Unit Installation
Installation of thermal insulation (cont.) Preparing the control unit installation 4. Pull burner cables fA and lÖ 1. Secure the bottom of the mounting panel with self−tapping forward through the clean−out screws B 3.9 × 9.5 on the side aperture (position surplus cable panel. - Page 17 Installation of thermal insulation (cont.) 7. Please note 6. Push the boiler temperature sensor lead § (supplied with the control Do not kink the capillary tubes, unit) through the aperture in the otherwise the sensor function may side panel, and push the back of be compromised.
- Page 18 Installation of thermal insulation (cont.) 8. Secure the side panel with the 9. Route the boiler temperature control unit above the short side sensor and capillary tubes to the panel using screws M 8 × 40. sensor well, and push in as far as possible.
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Page 19: H Top Panel Installation
Installation of thermal insulation (cont.) Top panel installation... - Page 20 Installation of thermal insulation (cont.) 1. Fit the finned panels on the l.h. 6. Secure the bottom of the finned top, centre and l.h. bottom panels with self−tapping screws together using oval screws B 3.9 × 9.5. M 6 × 10. 7.
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Page 21: H Installation Of Back Panel, Boiler Door And Cable Channel
Installation of thermal insulation (cont.) Installation of back panel, boiler door and cable channel 1. Fit the back panel onto the top of 3. Fit the strain relief to the burner the boiler, push the finned panels cable. into the tabs and secure with screws M 8 ×... - Page 22 Installation of thermal insulation (cont.) 6. Secure the cable channel with two 9. Pull all external cables through self−tapping screws B 3.9 × 9.5 to the cable duct to the control unit. the mounting panel. 10. Insert the coding card (included 7.
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Page 23: Burner Installation
Burner installation For burner installation, see separate burner documentation. H Install the burner plate (part of the H Drill the burner plate to suit, if the standard delivery). actual dimensions do not match the pre−drilled pattern. H The circle of burner fixing holes H In the case of different dimensions, and blast tube aperture match the dimensions of many well−known... -
Page 24: Burner Settings
Initial start−up For commissioning and adjustments, see the service instructions for boiler, burner and boiler control unit. Subject to technical modifications. Viessmann Werke GmbH & Co D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de...