Viessmann Vitocrossal 300 CT3 Series Installation Instructions Manual
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Viessmann Vitocrossal 300 CT3 Series Installation Instructions Manual

Viessmann Vitocrossal 300 CT3 Series Installation Instructions Manual

Gas-fired condensing boiler 638 to 3361 mbh 187 to 985 kw
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Installation Instructions

for use by heating contractor
Vitocrossal 300
CT3 Series
Gas-fired condensing boiler
Heating input:
638 to 3361 MBH
187 to 985 kW
VITOCROSSAL 300
Vitocrossal 300, CT3 boiler
with Vitotronic control
5285 873 - 02 12/2014
IMPORTANT
Please ensure that these instructions are read and
understood before commencing installation and
start-up. Failure to comply with these Installation
Instructions will render all warranties null and void.
Working on the equipment
The installation, adjustment, service and
maintenance of this product must be performed
by a licensed professional heating contractor,
who is qualified and experienced in the installation,
service and maintenance of hot water heating
boilers. There are no user serviceable parts on the
boiler, burner, or control.
Ensure main power supply to equipment, the
heating system and all external controls has been
deactivated. Close main oil or gas supply valve.
Take precautions in all instances to avoid
accidental activation of power during service work.
Improper installation, service or maintenance can
cause product/property damage, severe personal
injury, and/or loss of life.
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann Vitocrossal 300 CT3 Series

  • Page 1: Installation Instructions

    Installation Instructions for use by heating contractor Vitocrossal 300 CT3 Series Gas-fired condensing boiler Heating input: 638 to 3361 MBH 187 to 985 kW VITOCROSSAL 300 IMPORTANT Please ensure that these instructions are read and understood before commencing installation and start-up.

  • Page 2: Safety, Installation And Warranty Requirements

    Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the Warranty  boiler in the “Service Instructions” manual. Information contained in this and related product documentation must be read and followed.

  • Page 3: Fiberglass Wool And Ceramic Fiber Materials

    Safety Vitocrossal 300, CT3 Series Installation Safety, Installation and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber materials Suppliers of fiberglass wool products recommend the WARNING following precautions be taken when handling these materials: Inhaling of fiberglass wool and/or ceramic fiber Precautionary measures materials is a possible cancer hazard.

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 300, CT3 Series Installation Page Safety Safety, Installation and Warranty Requirements ....2 Product documentation ...........2 Licensed professional heating contractor ....2 Contaminated air ...........2 Advice to owner ............2 Warranty ..............2 Carbon monoxide ...........2 Fresh air ...............2 Equipment venting ..........2 Fiberglass wool and ceramic fiber materials ....3 Suppliers of ceramic fiber products recommend the following first aid measures: ......3...
  • Page 5 Table of Contents Vitocrossal 300, CT3 Series Installation Page Assembly Insulation Installation ..........19 Preparing the Control Unit Installation ......22 Insulation Installation ..........24 Back panel, combustion chamber door and cable channel installation ..........24 Top panel installation ...........25 Observation Port Installation ........26 Burner Installation ............26 Burner Blast Tube Insulation ........27 Packing Materials ..........27...

  • Page 6: Important Regulatory And Safety Requirements

    Safety Vitocrossal 300, CT3 Series Installation Important Regulatory and Safety Requirements For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...

  • Page 7: Codes

    For oil-fired boiler installation, use CSA B-139 in Canada - Operating Instructions and User’s Information Manual and NFPA 31 in the U.S. Always use latest editions of - Instructions of other Viessmann products utilized with codes. this installation - Installation codes mentioned in this manual In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local...

  • Page 8: About These Instructions

    General Information Vitocrossal 300, CT3 Series Installation About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below. Warnings draw your attention to the presence of WARNING potential hazards or important product information.

  • Page 9: Mechanical Room

    Set-up Vitocrossal 300, CT3 Series Installation Mechanical Room The Vitocrossal 300, CT3 boiler should be located in Do not use exhaust fans without adding additional a heated indoor space. The boiler should also be located provisions for fresh combustion air (e.g. fresh air fan) in near a floor drain and as close as possible to the vertical the boiler room and do not install the Vitocrossal 300 chimney or vent.
  • Page 10 Set-up Vitocrossal 300, CT3 Series Installation Minimum Clearances (continued) Overall length Overall width Length Width 1 with IN 1 Width 1 min. 5b in. (140 mm) Length of 12 in. boiler pad (160 mm) Width 2 Width 2 with IN 2 Legend Vent pipe connection Note: - Boiler shell, overall and foundation dimensions...

  • Page 11: Boiler Dimensions

    Set-up Vitocrossal 300, CT3 Series Installation Boiler Dimensions Dimensions Boiler Model CT3- (mm) (715) (715) (715) (751) (751) (751) (751) (751) (mm) (298) (298) (298) (325) (325) (325) (363) (363) (mm) (518) (518) (529) (577) (577) (577) (644) (644) (mm) (1854) (1854) (1854)

  • Page 12: Boiler Handling, Positioning And Adjustments

    Set-up Vitocrossal 300, CT3 Series Installation Boiler Handling, Positioning and Adjustments Please observe the minimum clearances starting on page 8. The boiler itself is mounted on a boiler pad. This boiler pad should be placed on a concrete or equivalent foundation. A recommended foundation size for each boiler model can be found on page 29.

  • Page 13: Assembly When Supplied In Sections

    Assembly Vitocrossal 300, CT3 Series Installation Assembly When Supplied in Sections CAUTION Do not put any tools or any 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.

  • Page 14: Water Side Connections

    A High temp. heating loop are available. Please enquire with your local B Low temp. heating loop Viessmann sales representative. C Pressure relief valve (must be installed within first 12 in. (305 mm) of piping) D Safety supply - alternate pressure relief valve location...

  • Page 15: Hydrostatic Test Procedure

    Boiler Connections Vitocrossal 300, CT3 Series Installation Hydrostatic Test Procedure Vitocrossal 300, CT3-17 to -89 All Vitocrossal boilers are factory tested (hydrostatic testing) to ASME requirements. The following testing procedure is to ensure that the boiler remained intact during shipping and handling. 1.

  • Page 16: Boiler Piping In Heating/Cooling Application

    Boiler Connections Vitocrossal 300, CT3 Series Installation Boiler Piping in Heating/Cooling Application The boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel to the boiler with appropriate valves Cooling unit Heating/ to prevent the chilled medium from entering the boiler.

  • Page 17: Initial System Fill

    Boiler Connections Vitocrossal 300, CT3 Series Installation Initial System Fill Treatment of boiler feed water should be considered The pressure relief valve must be attached to the top in areas of known problems, such as high mineral content tapping on the boiler shell as per diagram on page 13, and hardness.

  • Page 18: Condensate Connection

    Boiler Connections Vitocrossal 300, CT3 Series Installation Condensate Connection Note: The “amount of condensate” and the “flue gas temperature gross” graphs are independent of each other. 1. Locate the neutralization unit either behind or next to the boiler. 2. Trim the plastic hose supplied to the required dimension, and connect it as a P-trap (or with a siphon) to the condensate drain and the neutralization unit.

  • Page 19: Condensate Disposal

    3 and 4 on the pH scale. If local building requirements demand neutralizing the condensate before disposal, contact Viessmann Manufacturing Company Inc. for a correctly sized neutralization tank. The treated condensate will show pH values of between 6.5 and 9 and can then be disposed of into the waste water system.

  • Page 20: Assembly

    Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation All necessary parts are packed and shipped inside the CAUTION insulation cartons. The installation of the insulation should only be performed Do not put any tools or any other objects into the once all the piping has been attached to the boiler shell combustion chamber.
  • Page 21 Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation (continued) 10. Attach front panel with three screws M 8 x 10 to the mounting brackets. 11. Attach the back panels with three screws M 8 x 10 to the mounting brackets. 12.

  • Page 22: Preparing The Control Unit Installation

    Assembly Vitocrossal 300, CT3 Series Installation Preparing the Control Unit Installation 1. Attach the bottom of the mounting panel A with self-tapping screws B 3.9×9.5 to the side panel. 2. Attach the mounting panel B with two self-tapping screws B 3.9×9.5 on the back of the mounting panel (closed side oriented towards the boiler door).
  • Page 23 Maximum allowable operating temperature (fixed high limit) is 99° C (210 ° F). IMPORTANT For Viessmann pre-assembled control panels, follow instructions supplied with control panel. 8. Attach the side panel with the control unit above the short side panel using four screws M 8×40.

  • Page 24: Insulation Installation

    Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation Back panel, combustion chamber door and cable channel installation 1. Fit the finned panels on the top left, center and bottom left together using pan head screws M 6×10. 2. Hook the left finned panels into the threads of the spacer bolts and locate them in the side panel tab.

  • Page 25: Top Panel Installation

    Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation (continued) Top panel installation 1. Fit the back panel onto the top of the boiler, push the finned panels into the tabs and secure with four screws M 8×10 to the threaded studs. 2.

  • Page 26: Observation Port Installation

    The proper burner plate for desired burner is supplied minimum of 5½ in. (140 mm) of the combustion head by Viessmann length must be maintained (total length from flange). H Install the burner plate (part of the standard delivery).

  • Page 27: Burner Blast Tube Insulation

    Assembly Vitocrossal 300, CT3 Series Installation Burner Blast Tube Insulation Packing Materials IMPORTANT The combustion chamber door opening is smaller in diameter than the burner blast tube. Do not attempt to force the burner blast tube inside the combustion chamber door. This may damage the combustion chamber door refractory.

  • Page 28: Burner Settings

    Assembly Vitocrossal 300, CT3 Series Installation Burner Settings CAUTION Do not exceed the maximum gas input of a particular boiler model. At the highest burner stage verify the maximum input by clocking gas meter. See instructions supplied by burner manufacturer Venting Connection Use an AL29-4C®...

  • Page 29: Start-Up

    Start-Up Vitocrossal 300, CT3 Series Installation Initial Start-Up Pressure drop (primary circuit) The Vitocrossal 300 boiler is only suitable for heating systems with pumped heating water. For start-up and adjustments, see the service instructions for boiler, burner and boiler control unit CAUTION Do not fire the burner unless boiler and heating system...

  • Page 30: Appendix

    Appendix Vitocrossal 300, CT3 Series Installation Technical Data Boiler Model CT3- Input 1071 1389 1726 2160 2702 3361 (kW) (187) (248) (314) (407) (506) (633) (792) (985) 1044 1350 1675 2094 2616 3252 Output (kW) (183) (242) (306) (396) (491) (614) (767) (953)

  • Page 31: Boiler Model

    30% of rated input. Calculate the flue gas mass flow rate accordingly when the partial load differs from that stated above (subject to the burner mode).  For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.
  • Page 32 Vitocrossal 300 CT3 Series Installation...

This manual is also suitable for:

Vitocrossal 300 ct3-17Vitocrossal 300 ct3-22Vitocrossal 300 ct3-28Vitocrossal 300 ct3-37Vitocrossal 300 ct3-46Vitocrossal 300 ct3-57 ... Show all

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