Viessmann Vitocrossal 300 CA3 6.0 Installation And Service Instructions Manual

Category
Water heaters & boilers
Type
Installation And Service Instructions Manual

This manual is also suitable for

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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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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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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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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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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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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Viessmann Vitocrossal 300 CA3 6.0 Installation And Service Instructions Manual

Category
Water heaters & boilers
Type
Installation And Service Instructions Manual
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