Viessmann Vitocrossal 300 CA3 6.0 Installation And Service Instructions Manual

Installation and Service

Instructions

VITOCROSSAL 300

5790 733 - 05 06/2017

for use by heating contractor

Vitocrossal 300

CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0

Gas condensing boiler with cylinder burners

Read and save these instructions

for future reference.

Please file in Service Binder

Product may not be exactly as shown

IMPORTANT

H

Heating input: 2500 to 6000 MBH

(733 to 1758 kW)

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Safety, Installation and Warranty Requirements

Safety

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with

the instructions listed below and details printed in this manual can cause product/property damage, severe personal

injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information

found in manual subsections).

WARNING

Installers must follow local regulations with respect to

installation of carbon monoxide detectors. Follow the

Viessmann maintenance schedule of the boiler contained

in this manual.

Product documentation

Read all applicable documentation before commencing

installation. Store documentation near boiler in a

readily accessible location for reference in the future

by service personnel.

For a listing of applicable literature,

please see section entitled “Important

Regulatory and Safety Requirements”.

Warranty

Information contained in this and

related product documentation must

be read and followed. Failure to do

so renders the warranty null and void.

Licensed professional heating contractor

The installation, adjustment, service and maintenance

of this equipment must be performed by a licensed

professional heating contractor.

Please see section entitled

“Important Regulatory and Installation

Requirements”.

Contaminated air

Air contaminated by chemicals can cause by-products

in the combustion process, which are poisonous to

inhabitants and destructive to

Viessmann equipment.

For a listing of chemicals which

cannot be stored in or near the

boiler room, please see subsection

entitled “Mechanical room” in the

“Installation Instructions”.

Advice to owner

Once the installation work is complete, the heating

contractor must familiarize the system operator/

ultimate owner with all equipment, as well as safety

precautions/requirements, shutdown procedure, and

the need for professional service annually before the

heating season begins.

Carbon monoxide

Improper installation, adjustment, service and/or

maintenance can cause flue products to flow into

living space. Flue products contain poisonous carbon

monoxide gas.

For information pertaining to the

proper installation, adjustment, service

and maintenance of this equipment to

avoid formation of carbon monoxide,

please see subsection entitled

“Mechanical room” and “Venting

requirements” in the “Installation Instructions”.

Fresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

For information pertaining to the

fresh air requirements of this product,

please see subsection entitled

“Mechanical room” in the “Installation

Instructions”.

Equipment venting

Never operate boiler without an installed venting

system. An improper venting system can cause

carbon monoxide poisoning.

For information pertaining to

venting and chimney requirements,

please see section entitled “Venting

Connection”. All products of

combustion must be safely vented

to the outdoors.

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Safety, Installation and Warranty Requirements (continued)

Safety

WARNING

Inhaling of fiberglass wool and/or ceramic fiber

materials is a possible cancer hazard. These materials

can also cause respiratory, skin and eye irritation.

Fiberglass wool and ceramic fiber materials

WARNING

Appliance materials of construction, products of

combustion and the fuel contain alumina, silica, heavy

metals, carbon monoxide, nitrogen oxides, aldehydes

and/or other toxic or harmful substances which can

cause serious injury or loss of life and which are

known to the State of California to cause cancer,

birth defects and other reproductive harm. Always

use proper safety clothing, respirators and equipment

when servicing or working nearby the appliance.

The state of California has listed the airborne fibers of

these materials as a possible cancer hazard through

inhalation. When handling these materials, special care

must be applied.

First aid measures

- If eye contact occurs, flush eyes with water to remove

dust. If symptoms persist, seek medical attention.

- If skin contact occurs, wash affected areas gently

with soap and warm water after handling.

Suppliers of fiberglass wool products recommend the

following precautions be taken when handling these

materials:

- Avoid breathing fiberglass dust and contact with

skin and eyes.

- Use NIOSH approved dust/mist respirator.

- Wear long-sleeved, loose fitting clothing, gloves

and eye protection.

- Wash work clothes separately from other clothing.

Rinse washer thoroughly.

- Operations such as sawing, blowing, tear-out and

spraying may generate airborne fiber concentration

requiring additional protection.

Codes

The installation of this unit shall be in accordance with

local codes. In the absence of local codes, use:

CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning

Appliances for Canada. For U.S. installations, use the

National Fuel Gas Code ANSI Z223.1. Always use latest

editions of codes.

In Canada all electrical wiring is to be done in accordance

with the latest edition of CSA C22.1 Part 1 and/or local

codes. In the U.S., use the National Electrical Code ANSI/

NFPA 70.

The heating contractor must also comply with the Standard

for Controls and Safety Devices for Automatically Fired

Boilers, ANSI/ASME CSD-1 where required by the authority

having jurisdiction.

Mechanical room

Ensure the mechanical room complies with the

requirements of the System Design Guidelines and/or

Technical Data Manual.

In addition, see section entitled “Mechanical Room” on

page 11 in this manual.

Viessmann recommends installation of an additional

electrical disconnect switch and a fuel shut-off valve (if

possible) outside the mechanical room or enclosed area

of installation.

The maximum room temperature of the mechanical room

where the boiler is located must not exceed 104°F (40°C).

Suppliers of ceramic fiber products recommend the

following first aid measures:

- Respiratory tract (nose and throat) irritation:

If respiratory tract irritation develops, move the

person to a dust free location.

- Eye irritation: If eyes become irritated, flush immediately

with large amounts of lukewarm water for at least 15

minutes. Eyelids should be held away from the eyeball

to ensure thorough rinsing. Do not rub eyes.

- Skin irritation: If skin becomes irritated, remove soiled

clothing. Do not rub or scratch exposed skin.

Wash area of contact thoroughly with soap and water.

Using a skin cream or lotion after washing may be

helpful.

- Gastrointestinal irritation: If gastrointestinal tract

irritation develops, move the person to a dust free

environment.

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Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service

Table of Contents

Safety

General Information

Installation

System Layout

Venting

Page

Safety, Installation and Warranty Requirements ............ 2

Important Regulatory and Installation Requirements ........8

About these Installation Instructions ...........................10

Product Information ..................................................10

Mechanical Room .....................................................11

For Retrofit Applications ............................................11

Recommended Minimum Service Clearance .................12

Unpacking and Placement of Boiler .............................13

Reducing Boiler Height ........................................... 13

Preparing the Boiler ..................................................14

Water Side Connection ........................................... 14

Boiler Connections ....................................................15

Electrical Connections............................................ 18

Activating the Boiler Section Valves ......................... 35

Extension EA1 Accessory (optional) ......................... 36

Making the LON Connection ......................................37

Vitocom 100, LAN 1 ................................................38

Vitocom 100, LAN 1 Requirements ............................39

Operation with Vitotrol App .................................... 40

Operation with Vitotrol 100 User Interface ..................41

Checking Network Settings ..................................... 41

Vitocom 100, LAN 1 Internal Overview .......................42

Connecting to the Network (LAN) ...............................42

Vitocom 100, LAN 1 Display and Control Elements ..... 43

Switching on the Vitocom 100, LAN 1 ........................43

Configuring Network Using Static IP ...........................44

Registering the Vitocom 100, LAN 1 ........................ 45

Function Test ..........................................................45

Enabling Maintenance ............................................ 46

Return Vitocom 100, LAN 1 to Factory Set Condition .. 46

Troubleshooting Measures for Vitocom 100, LAN 1 ......47

Connecting Flue Gas Pipe ..........................................48

Connecting Neutralization System ..............................49

Condensate Connection ............................................50

Gas Connections ......................................................51

Initial System Fill ................................................... 54

General ...................................................................55

System Layout 1 .................................................. 56

System Layout 2 .................................................. 57

Boiler Piping in Heating/Cooling Application .................58

General Venting Information ......................................59

Connecting Combustion Air Intake for Direct Vent ........62

Additional Requirements for Stainless Steel

Vent Pipe Material ....................................................62

Requirement for UL/ULC Listed Rigid SS/PP(s)

Vent Pipe Material ....................................................63

Vent Requirements ................................................ 64

Direct Venting (Two Pipe System) ..............................65

Side Wall Venting ................................................. 66

Component Installation Guide .................................. 66

Elbow - Equivalent Length ...................................... 66

Vent Termination Location Requirements - Vertical .......67

Installation of Support System - PP(s) .........................67

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5790 733 - 05

Vitocrossal 300 CA3 - 3.5, 4.0, 5.0 and 6.0 Installation/Service

Venting Options - Stainless Steel/PP(s)

General Service Information

Service

Table of Contents

Two Pipe System - Vertical Exhaust/

Vertical Air Intake ....................................................68

Two Pipe System - Horizontal Exhaust/

Horizontal Air Intake .................................................70

Two Pipe System - Vertical/Horizontal Installations .......71

Individual Burner Intake Ducting .............................. 72

Single Pipe System - Vertical Exhaust/

Room Air Dependant .................................................73

Single Pipe System - Horizontal Exhaust/

Room Air Dependant .................................................74

Multiple Boiler Installations ..................................... 75

Service Equipment ....................................................76

Important Regulatory and Installation Requirements ......77

Safety Instructions ................................................ 78

Filling the Heating System with Water and Ventilating .. 80

Filling Condensate Trap with Water ............................80

Checking the Type of Gas .........................................80

Operating the System ........................................... 81

Adjusting the Heating Curve ......................................84

Integrating the Control Unit into the LON.....................86

Preparing for Service Work on the Boiler and Burner .....88

Reducing Operational Output (if required) ....................90

Checking Static and Connection Pressure ....................91

Checking the Rotary Damper Setting ..........................92

Checking the Burner Damper Setting...........................92

Measuring CO2 Content ............................................93

Displaying Ionization Current .................................... 95

Turning the System Off .............................................95

Dismantling the Burner........................................ 96

Burner Parts ...........................................................98

Display and Programming Unit of Burner Control Unit ...99

Coding Card on Burner Control Unit ...........................99

Burner Control Unit ................................................ 100

Fuel Conversion NG to LPG ..................................... 100

Converting Gas Type.............................................. 102

Burner Interface Panel .............................................103

3A and 3B Boiler Temperature Sensor Description ......104

Boiler Water Temperature Sensor .............................105

Boiler Secondary Temperature Sensor ....................... 106

Manual Reset Limits ............................................... 107

Gas Valve ............................................................. 108

Air Pressure Switches ...........................................108

Ignition Unit .......................................................... 111

Ignition Cables .......................................................112

Rotary Damper and Servomotor ...............................112

Replacing the Solenoid Valve ...................................112

Fan ....................................................................... 113

Checking and Cleaning the Burner Tube ....................113

Checking the Ignition Electrodes and Ionization Electrode . 114

Cleaning the Burners .............................................114

Cleaning the Combustion Chamber and

Heating Surfaces ...................................................115

Checking Heating Water Connections for Leakage ...... 116

Cleaning the Condensate Drainage System ................116

Page

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Service (continued)

Function Description

Coding Levels

Coding Level 1

Coding Level 2

Service Scans

Troubleshooting

Table of Contents

Further Assembly and Commissioning .......................117

Checking for Flue Gas Leakage .............................. 117

Automatic Leakage Test for Valves of the Combined

Gas Valve ............................................................. 117

Checking On-site Gas Connections for Leakage ..........118

Taking Final Measurement Reading ..........................118

Checking the Water Conditions ...............................118

Checking Expansion Tank and System Pressure ........ 121

Mixing Valve Movement and Leak Check ...................121

Checking Air Intake in the Installation Room

(visual check) ........................................................ 122

Replacing the Supply Air (for room air dependant

operation) ........................................................................ 122

Instructing the Operator of the System .....................122

Operating and Service Documents ............................ 122

Boiler Water Temperature Control ...........................123

Cascade Control Unit ..............................................123

Heating Circuit Control ............................................128

DHW Tank Temperature Control ............................... 132

Calling up Coding Levels ..................................... 135

Resetting Coding to their Factory Set Condition .........135

“General” Group .....................................................136

“Combustion Controller” Group ................................138

“Boiler” Group .......................................................138

“Cascade” Group ..................................................139

“DHW” Group ........................................................ 141

“Solar” Group .................................................. 142

“Heating Circuit...” Group....................................... 143

“General” Group .....................................................147

“Combustion Controller” Group ................................155

“Boiler” Group .......................................................156

“Cascade” Group ..................................................156

“DHW” Group ........................................................ 159

“Solar” Group .................................................. 161

“Heating Circuit...” Group....................................... 165

Calling up the Service Menu ...................................171

Leaving the Service Menu .......................................172

Change Passwords .................................................172

Resetting all Passwords to Factory Settings .............172

Scanning Operating Data ........................................ 172

Resetting Operating Data

.......................................173

Brief Scan ............................................................. 173

Carrying Out an Actuator Test ................................174

Checking Sensors ...................................................175

Maintenance Display ...............................................175

Fault Display .......................................................... 176

Boiler System Fault Codes ........................................177

Burner Fault Codes ................................................183

Sensors ...............................................................186

Page

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Burner Control Unit ................................................187

Resetting Operating Parameters to Factory Settings ....191

Manual Mode and Service Display ............................191

Burner Control Unit Flow Diagram ............................192

Faults ................................................................... 194

Fault Codes ....................................................... 195

Faults Without Fault Display ....................................198

Burner Control unit Connection Diagram ....................199

Boiler Connections ..................................................201

Overview .............................................................. 203

PCB Extension for Heating Circuits 2 and 3 with

Mixing Valve .........................................................204

PCB Low Voltage ................................................ 204

PCB 120V~ .......................................................... 205

Parts Lists ...........................................................206

Technical Data ....................................................... 218

Boiler Dimensions ............................................... 220

Requirements for Water Conditions ...........................221

Maintenance Records .......................................... 222

Maintenance Schedule ............................................ 222

Table of Contents

Page

Burner Control Unit

Connection and Wiring Diagrams

Parts

Specifications

Inspection and Maintenance

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

General Information

Important Regulatory and Installation 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:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall

horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired

carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas

equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery

operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the

dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be

the responsibility of the property owner to secure the services of qualified licensed professional for the

installation of hard-wired carbon monoxide detectors.

a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or

an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on

the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30) days to comply with the above requirements;

provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector

with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance

with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the

building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal

for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no

less than one-half (b) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment

shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide

detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current

edition of NFPA 54 as adopted by the Board; and

2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure

separate from the dwelling, building or structure used in whole or in part for residential purposes.

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Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

WARNING

Failure to ensure that all flue gases have been safely

vented to the outdoors can cause property damage,

severe personal injury, or loss of life. Flue gases may

contain deadly carbon monoxide.

CAUTION

Under certain climatic conditions some building materials

may be affected by flue products expelled in close

proximity to unprotected surfaces. Sealing or shielding

of the exposed surfaces with a corrosion resistant

material (e.g. aluminum sheeting) may be required to

prevent staining or deterioration. The protective material

should be attached and sealed (if necessary) to the

building before attaching the vent termination. It is

strongly recommended to install the vent termination

on the leeward side of the building.

For Polypropylene venting systems only

Minimum and maximum wall thickness through which the

horizontal vent-air intake termination may be installed:

Minimum: 1 in. (25.4 mm)

Maximum: 30 in. (762 mm)

Vent-air intake system must be properly installed and sealed.

If PP(s) venting system passes through an unheated space,

such as an attic, it must be insulated.

The insulation must have an R value sufficient to prevent

freezing of the condensate. Armaflex insulation with b in.

thickness and higher can be used.

Venting clearance to combustibles (Stainless Steel /

Polypropylene)

As per vent manufacturer’s requirements. Working on the equipment

The installation, adjustment, service, and maintenance of

this boiler must be performed by a licensed professional

heating contractor who is qualified and experienced in the

installation, service and maintenance of hot water boilers.

There are no user serviceable parts on the boiler, burners

or control.

Note: The completeness and functionality of field supplied

electrical controls and components must be verified

by the heating contractor. This includes low water

cut-offs, flow switches (if used), staging controls,

pumps, motorized valves, air vents, thermostats, etc.

Ensure main power supply to equipment, the heating

system and all external controls have been deactivated.

Close main gas supply valve. Take precautions in all

instances to avoid accidental activation of power during

service work.

Technical literature

Literature for the Vitocrossal 300, CA3 boiler:

- Technical Data Manual

- Installation and Service Instructions

- Operating Instruction

- Instructions of other products utilized and installed

- Installation codes mentioned in this manual and as

locally applicable

Note: Leave all literature at the installation site and

advise the system operator/ultimate owner where

the literature can be found. Contact Viessmann for

additional copies.

This product comes with several safety instruction

labels attached. Do not remove!

Contact Viessmann immediately if replacement

labels are required.

ASME CSD-1 Standard

The ASME CSD-1 standard is published by ASME

(American Society of Mechanical Engineers) and covers the

requirements for the assembly, installation, maintenance,

and operation of the controls and safety devices on

automatically operated boilers directly fired with gas, oil,

gas-oil, or electricity. The gas valve of this boiler meets the

requirements as set forth in the ASME CSD-1 standard.

IRI (Industrial Risk Insurers)

IRI (Industrial Risk Insurers) requirements for boilers have

been replaced by GE Global Asset Protection (GAP)

Services requirements, please refer to section describing

GE GAP requirements.

GE GAP (Global Asset Protection)

GE GAP Services publishes GE GAP Guidelines for various

risks including boiler combustion codes and standards.

In many cases, they adopt other existing nationally

recognized standards. GE GAP Guidelines replace and

eliminate the former IRI requirements. GE GAP requires

compliance with ASME CSD-1 up to 12,500,000 BTU.

FM (Factory Mutual) Global

FM Global (formerly Factory Mutual Systems) participates

on the ASME CSD-1 Committee and has aligned their

requirements with those of ASME CSD-1. FM Gobal will

accept a standard UL or ETL Listed Boiler complying with

ASME CSD-1 up to 2,500,000 BTU.

From 2.5 to 12.5 Million BTU, they still align with the

ASME CSD-1 standard but may require additional FM

Global approved components.

Note: The local GE GAP or FM Global Inspectors have the

right to request additional safeguards for unusual

risks, but the ASME CSD-1 standard as outlined

is normally accepted as meeting their requirements.

Important Regulatory and Installation Requirements (continued)

General Information

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Product Information

High efficiency gas-fired hot water condensing boiler.

For operation with modulating boiler water temperatures

in closed loop, forced circulation hot water heating

systems.

The Vitocrossal 300, CA3 boilers are CSA certified with

Viessmann burners which must be used in conjunction

with this boiler series.

The proper burner size must be verified and the burners

are factory adjusted so that the maximum input of the

appropriate boiler size is always observed. The gas burners

must always be installed according to the instructions

provided by the burner manufacturer.

The boiler model selected should be based on an accurate

heat loss calculation of the building. The boiler selected

must be compatible with the connected radiation.

WARNING

Exposing the boiler to pressures and temperatures in

excess of those listed will result in damages, and will

render warranty null and void.

The Vitocrossal 300, CA3 boiler is suitable for a maximum

operating pressure of 160 psig and a maximum boiler

water temperature of 210°F (99°C).

This boiler does not require a flow switch.

About these Installation 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.



IMPORTANT

Warnings draw your attention to the presence of

potential hazards or important product information.

Cautions draw your attention to the presence of

potential hazards or important product information.

Helpful hints for installation, operation or maintenance

which pertain to the product.

This symbol indicates that additional, pertinent

information is to be found.

This symbol indicates that other instructions must

be referenced.

WARNING

Indicates an imminently hazardous situation which,

if not avoided, could result in death, serious injury

or substantial product/property damage.

CAUTION

Indicates an imminently hazardous situation which,

if not avoided, may result in minor injury or product/

property damage.

General Information

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service General Information

Mechanical Room

The Vitocrossal 300, CA3 boiler should be located in a

heated indoor space. The boiler should also be located

near a floor drain and as close as possible to the vertical

chimney or vent.

Whenever possible, install boiler near an outside wall so

that it is easy to duct fresh air directly to the boiler area.

Install boiler on flooring capable of supporting the weight

of the boiler filled with water.

Do not use exhaust fans without adding additional

provisions for fresh combustion air (e.g. fresh air fan)

in the boiler room and do not install the Vitocrossal 300,

CA3 boiler in rooms with refrigeration equipment. This

boiler requires uncontaminated air for safe operation -

do not install where chemicals are stored.

For Retrofit Applications

Before boiler is connected to piping/heating system,

(which has been previously in service) the piping must be

flushed with city pressure water (50-60 psi) to remove

sludge and other contaminates.

Failure to flush out the heating system piping may result

in restricted flow and/or deposits resulting in boiler failure.

This failure is not covered under warranty.

Do not operate when air is polluted with halogenated

hydrocarbons (e.g. as in aerosols, paints, solvents

and cleaning agents)

Prevent very dusty conditions

Prevent high levels of humidity

Prevent freezing and ensure good ventilation.

Otherwise, the system may suffer faults and damage.

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Recommended Minimum Service Clearances

Preinstallation

Mechanical room

Avoid air contamination by halogenated hydrocarbons

(e.g. as in sprays, paints, solvents and cleaning agents)

Avoid very dusty conditions

Avoid high levels of humidity

Protect against frost and ensure good ventilation,

otherwise the system may suffer faults and damage.

In rooms where air contamination from halogenated

hydrocarbons is to be expected, operate the boiler

using only direct vent (sealed combustion) operation

only.

Legend

A Boiler

*1 Clearance for vent pipe installation.

B Boiler combustion air intake vent

To enable convenient installation and maintenance,

observe the stated clearance dimensions. Maintain the

minimum clearances where space is tight.

CA3

Model

2.5 3.0 3.5 4.0 5.0 6.0

a in.

(mm)

31b

(800)

31b

(800)

31b

(800)

31b

(800)

31b

(800)

31b

(800)

b*1 in.

(mm)

30

(760)

30

(760)

30

(760)

30

(760)

30

(760)

30

(760)

c in.

(mm)

39e

(1000)

39e

(1000)

39e

(1000)

39e

(1000)

39e

(1000)

39e

(1000)

Top

clearance

31b

(800)

31b

(800)

31b

(800)

31b

(800)

31b

(800)

31b

(800)

Minimum clearances to combustibles

CA3

Model

2.5 3.0 3.5 4.0 5.0 6.0

Top 0

Sides 0

Flue per vent manufacturer’s specifications

Front 0

Floor combustible

CA3 2.5, 3.0, 3.5 and 4.0

CA3 5.0 and 6.0

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5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

* CA3 boilers 2.5-3.0 3.5-6.0

Total height in.

(mm)

78c

(1999)

84

(2136)

Height excluding upper panels, upper in.

frame elements, burners and piping (mm)

77

(1977)

77c

(1975)

Positioning boiler

The boiler must be placed on a foundation.

A minimum height of 4 in. (100 mm) is required in order

to allow for the condensate siphon connection.

Preinstallation

Unpacking and Placement of Boiler

Unpacking boiler

1. Unscrew back panel.

2. The remaining packaging parts are screwed together.

Open the packaging parts in the following order:

Front panel

Top panel

Left side panel

Right side panel

3. Raise boiler from the packaging platform with a lift

truck or forklift.

It is essential to use appropriate lifting devices

certified of lifting to a minimum of the boiler

weight.

Lifting the boiler

1. There is a boiler lifting location for the forks of a lift

truck or forklift on the right and left side of the boiler.

2. There is a boiler lifting location for the forks of a lift

truck or forklift on the front of the boiler.

IMPORTANT

WARNING

If flue gas connection is damaged leakage may occur.

Do not lift boiler at the flue gas connection.

When lifting the boiler from the side ensure the forks of

the lift truck or forklift are centered. Refer to the crosshair

mark located on the side of the boiler.

Reducing Boiler Height

Reducing the overall height of the boiler during placement

The overall boiler height can be reduced for placement.

Panels, frame elements with piping and burners can be

dismantled for this purpose.

4. Remove burners. See page 96.

1. Release gas connection.

2. Disconnect electrical connections.

3. Dismantle electrodes.

4. Disconnect upper burner section and extract with

lifting mechanism.

Note: A lifting mechanism that can be mounted to

the boiler frame is available as an accessory.

5. Dismantle upper frame profiles.

1. Dismantle panels.

Top panels

Upper side panels

Upper rear panel

2. Dismantle boiler supply header.

3. Dismantle upper frame profile.

Dismantle the upper panels and upper frame elements

with piping and burners

* Height does not include the concrete pad or seismic

brackets.

CA3

Model

2.5 3.0 3.5 4.0 5.0 6.0

a in.

(mm)

74c

(1900)

74c

(1900)

82f

(2100)

82f

(2100)

114d

(2900)

114d

(2900)

b in.

(mm)

33

(860)

33

(860)

39e

(1000)

39e

(1000)

39e

(1000)

39e

(1000)

lb.

(kg)

4388

(1990)

4388

(1990)

4982

(2260)

5093

(2310)

6592

(2990)

7187

(3260)

Boiler weight

With seismic feet (available for models 2.5 thru 6.0)

Boiler model 2.5 3.0 3.5 4.0 5.0 6.0

a in.

(mm)

85a

(2165)

85a

(2165)

94

(2388)

94

(2388)

125

(3175)

125

(3175)

b in.

(mm)

48a

(1225)

48a

(1225)

53

(1346)

53

(1346)

53

(1346)

53

(1346)

14

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Installation

Note: Make all connections free of load and torque stresses.

The heating system must be properly flushed, especially

if the Vitocrossal 300, CA3 boiler is connected to an

existing heating system in a retrofit application.

See page 11 for details.

Connect the system to the boiler according the diagram

on page 55.

Note: All connections which are not being utilized for

water connections or for controls must be properly

closed.

The supplied air vent and pressure relief valve must be

installed on the supply header of the boiler - the alternate

pressure relief valve location may be in the boiler supply

line. The piping to the precharged expansion tank, as well

as any automatic feed water required, must be connected

to the boiler return. Boiler pump shall be installed on

return pipe, pumping water into the boiler.

The supplied low water cut-off should be installed directly

on the safety header of the boiler or may be installed in

the boiler piping above the pressure vessel.

Note: Piping diagrams for specific system layouts are

available. Please enquire with your local Viessmann

sales representative.

IMPORTANT

The Vitocrossal 300, CA3 boiler is only suited for hot

water heating. Do not install a 4-way mixing valve,

bypass valve or similar.

Water Side Connection

Preparing the Boiler

1. Once removed from the wooden shipping pallet from

the boiler base. Remove the 4 leveling bolts A from

boiler’s accessory package and install into the four

corners of the boiler base.

Note: When using seismic brackets B (optional

accessory) do not install levelling bolts.

2. It is recommended to place a flat piece of steel plate

under each leveling bolt for better weight distribution

and adjustment.

3. Level the boiler, by adjusting the floor levelling bolts.

Note: It is recommended that the levelling bolts included

with the boiler are used when installing the boiler

on uneven surfaces.

Refer to the Seismic bracket Installation

Instructions when using the optional seismic

mounts.

15

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Boiler Connections

Safety Header

1. Locate safety header on the main supply header.

Water pressure: 160 psi (11 bar)

Testing pressure: 240 psi (16.5 bar)

Min. water pressure: 8 psi (0.5 bar)

Note: The minimum water pressure is necessary for safe

operation.

Note: All boilers must have a pressure relief valve.

Note: Make all connections free of load and torque stresses.

CAUTION

Do not connect heating system to safety header.

Legend

1 Boiler return: (ANSI 4 in. for models 2.5, 3.0, 3.5,

4.0 and 5.0 and ANSI 6 in. for model 6.0) *1

2 Boiler supply: (ANSI 4 in. for models 2.5, 3.0, 3.5,

4.0 and 5.0 and ANSI 6 in. for model 6.0) *1

3 Safety header: (Pressure relief valve, low water cutoff,

automatic air vent and temperature/pressure gauge)

A Hex bushing b in. x e in.

B Air vent with shut-off base

C Plug b in.

D Reducer 2 in. to 1 in. for models 2.5 and 3.0,

2 in. to 1a in. for models 3.5 and 4.0,

2 in. to 1b in. for models 5.0 and 6.0

E Nipple 1 in. for models 2.5 and 3.0

1a in. for models 3.5 and 4.0

1b in. for models 5.0 and 6.0

F Pressure relief valve, 75 psi *2

G Low water cutoff

H Temperature/pressure gauge

4 Drains:

I Nipple 1b in. x 10 in.

J Reducer 1b in. x c in.

K Sediment faucet c in.

5 Gas line fittings:

L Gas gas shut-off valve,

2b in. for models 2.5, 3.0, 3.5

and 4.0, 3 in. for models 5.0 and 6.0

*1 Counter flanges, gaskets and hardware (field supplied)

*2 Alternate pressure relief valves are available depending

on operating pressure requirements. Contact your local

Viessmann sales representative for details.

Installation

16

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Installation

Boiler Connections (continued)

Hydrostatic test procedure

All Vitocrossal 300, CA3 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. Isolate boiler from hydronic heating system using

isolating valves (i.e. expansion tank, feed water valve,

pressure relief valve etc.).

2. Remove pressure relief valve from the boiler and cap

pipe outlet.

3. Fill boiler with city water and pressurize it to one and

a half (1½) times the maximum working pressure of

boiler. The pressure must be controlled such that it

will never be 10 psig higher than the testing pressure.

Max. allowable working pressure: 160 psig

Testing pressure: 240 psig (do not exceed 250 psig)

4. Monitor pressure over a period of approximately one

hour to ensure that the pressure remains constant and

steady at 240 psig.

5. Should there be a drop in pressure, ensure that

all fittings are secure and tight. Check all flanged

connections with a flashlight.

6. Open the boiler combustion chamber and inspect with

a flashlight the front portion of the Inox-Lamellar heat

exchanger sections for system water or fluid.

7. If test is successful, reinstall all hydronic system

components and refill the boiler with water or system

fluid.

WARNING

Never expose the boiler to any pressures higher than

250 psig during testing.

Legend

A Boiler supply

B Temperature/pressure gauge

C Pressure relief valve

D Boiler return

E Drain valve

F Precharged expansion tank

G Automatic fill

H Condensing water drain

I Flue gas test port

WARNING

Fill only suitable water in boiler (refer to Service

instructions). Unsuitable water quality may damage boiler.

17

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Boiler water drain valve

Using a water drain valve facilitates the drainage of a heat

exchanger. The supplied drain valve must be installed in

each boiler section before filling.

Boiler Connections (continued)

Installation

1. Locate and remove drain plug for each boiler section.

2. Install drain valve assembly for each boiler section as

shown.

Legend

A 1b in. x 10 in. nipple

B 1b in. to c in. reducer

C c in. sediment faucet

Installing the isolation valve handle

Remove the isolation valve handle A from the accessory

pack and insert it into the receiver handle B of the

isolation valve until it locks into place. Repeat for all valves.

Note: The handle is only used for initial installation and

for service. The handle must be removed prior to

putting the boiler into operation.

18

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

The cable trays are on the left side of the boiler.

Electrical Connections

Installation

Cable routing on boiler

IMPORTANT

Route power supply cables and low voltage cables

separately using the cable trays provided.

Legend

A Upper cable tray for power supply cables

(e.g. boiler power supply)

B Lower cable tray for low voltage cables

(e.g. sensor cables)

1. Remove the screws holding the top panels and lift

and remove the top panels.

2. Lift and remove upper front panel.

3. Lift and remove left side panels.

4. Using supplied ‘panel key’, unlock the front panel

and swing door open.

5. Remove upper and lower front panels for the

Vitotronic 300 GW6C control.

19

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Electrical Connections (continued)

Installation

Legend

A Supply temperature sensors heating circuits M2/M3

B External LON participants (i.e. Vitotronic 200-H)

C Low voltage/sensor connections

D Boiler power supply connection

E Pumps/mixing valve connections

F Disconnect switch with lockout provision

G Vitocom 100 LAN1

Connection overview for CA3 2.5 and 3.0

20

5790 733 - 05

Vitocrossal 300 CA3 Series 2.5 to 6.0 Installation/Service

Electrical Connections (continued)

Installation

Connection overview for CA3 3.5, 4.0, 5.0 and 6.0

Legend

A Supply temperature sensors heating circuits M2/M3

B External LON participants (i.e. Vitotronic 200-H)

C Low voltage/sensor connections

D Boiler power supply connection

E Pumps/mixing valve connections

F Internal disconnect switch (with lockout provision)

G Vitocom 100 LAN1

*1 Boiler section 3 control unit (5.0 and 6.0 only)

*1

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