Viessmann VITOCROSSAL 300 Installation Instructions Manual

Installation instructions

for contractors

VIESMANN

Vitocrossal 300

Type CM3

Gas condensing boiler with MatriX radiant burner

VITOCROSSAL 300

5862 417 GB 11/2014 Dispose after installation.

Please follow these safety instructions closely to

prevent accidents and material losses.

Safety instructions explained

!Please note

This symbol warns against the risk of material

losses and environmental pollution.

Note

Details identified by the word "Note" contain additional

information.

Target group

These instructions are exclusively intended for quali-

fied contractors.

■Work on gas installations must only be carried out by

a registered gas fitter.

■Work on electrical equipment must only be carried

out by a qualified electrician.

Regulations

Observe the following when working on this system:

■Statutory regulations regarding the prevention of

accidents

■Statutory regulations regarding environmental pro-

tection

■The Code of Practice of relevant trade associations

■all current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE [and all local standards].

aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and

ÖVE

cSEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS guideline 1942: LPG, part 2

Working on the system

■Isolate the system from the power supply (e.g. by

removing the separate fuse or by means of a mains

isolator) and check that it is no longer 'live'.

■Safeguard the system against reconnection.

■Where gas is used as the fuel, close the main gas

shut-off valve and safeguard it against unintentional

reopening.

Safety instructions

5862 417 GB

1. Information Symbols ................................................................................................. 4

Intended use .......................................................................................... 4

Clearance dimensions ........................................................................... 4

2. Installation sequence Siting and levelling the boiler ................................................................. 5

Fitting the thermal insulation .................................................................. 6

Connections on the heating water side .................................................. 8

Safety connections ................................................................................ 8

Making connections on the flue gas side ............................................... 9

■Exhaust gas connection ..................................................................... 9

■Condensate drain pipe ....................................................................... 9

■Neutralising system (if included) ......................................................... 9

Mounting the thermal insulation and control unit ................................... 10

Mounting the burner ............................................................................... 13

Commissioning and adjustment ............................................................. 13

Index

5862 417 GB

Symbol Meaning

Reference to other document containing

further information

Additional information, not safety relevant

Step:

The numbering corresponds to the se-

quence of work.

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions. It is only designed for the heating of water that is

of potable water quality.

Intended use presupposes that a fixed installation in

conjunction with permissible, system-specific compo-

nents has been carried out.

Commercial or industrial usage for a purpose other

than heating the building or DHW shall be deemed

inappropriate.

Any usage beyond this must be approved by the man-

ufacturer in each individual case.

Incorrect usage or operation of the appliance (e.g. the

appliance being opened by the system user) is prohibi-

ted and will result in an exclusion of liability. Incorrect

usage also occurs if the components in the heating

system are modified from their intended use (e.g. if the

flue gas and ventilation air paths are sealed).

Clearance dimensions

600 450

200

Fig.1

Symbols

5862 417 GB

!Please note

Damage to the flue outlet can result in leaks.

Never lift or move the boiler by the flue outlet.

Note

A suitable condensate drain (maximum 50 mm above

floor level) must be available in the installation room if

the boiler is installed at ground level.

±15

Fig.2

1. Screw the adjustable feet into the base rails. The

adjustable feet are in the same bag as the type

plate.

Note

If a neutralising system is being fitted, wind out the

adjustable feet as far as possible.

2. Using the adjustable feet, position the boiler so it

rises slightly towards the back (max. 5 mm over the

boiler length). No special foundations are required.

Siting and levelling the boiler

5862 417 GB

Note

All components required for fitting the thermal insula-

tion can be found in the box with the thermal insula-

tion.

Fig.3

Fitting the thermal insulation

5862 417 GB

90°

Fig.4

Fitting the thermal insulation (cont.)

5862 417 GB

Fig.5

ASafety connection (safety valve and air vent valve)

G 1¼

BBoiler flow PN 6 DN 50

CFemale connection for control equipment R ½

DFemale connection for minimum pressure switch

(low water indicator) R ½

EBoiler return 2

PN 6 DN 40

FBoiler return 1

PN 6 DN 50

GDrain and expansion vessel R 1

HCondensate drain R ½

Note

The Vitocrossal is only suitable for fully pumped hot

water heating systems.

Never install 4-way mixers, overflow valves or other

flow/return bypass devices.

Never connect heat consumers to the safety connec-

tion.

1. Thoroughly flush the heating system.

2. Connect the heating circuits.

■Connecting a single heating circuit: Connect the

heating return to boiler return F.

■Connecting 2 heating circuits: Connect the heat-

ing circuit with the higher temperature level to

boiler return E.

Connect at least 15 % of the boiler heating output

to boiler return F.

Safety connections

Safety equipment block installation instructions

1. Install the safety lines.

Safety valve minimum cross-

sections

Inlet connection

■87 kW DN 20

■115 and 142 kW DN 25

Discharge pipe

■87 kW DN 25

■115 and 142 kW DN 32

Pipe to the expansion vessel DN 20

2. Check the connections on the heating water side

for leaks.

Permiss. operating pres-

sure:

4 bar/0.4 MPa

Test pressure: 5.2 bar/0.52 MPa

Connections on the heating water side

5862 417 GB

Low water indicator

Tests have verified that the low water indicator speci-

fied by EN 12828 is not required.

Note

Equip boilers with a safety valve that is type-tested

according to TRD 721 [or local regulations] and is

identified in accordance with the relevant system.

Making connections on the flue gas side

Exhaust gas connection

Fig.6

1. Connect the flue outlet to the flue via the shortest

possible run to the chimney, maintaining a slight

rise (min. 3°). Avoid sharp kinks.

2. Insert the boiler flue connection (accessories) into

the flue outlet as far as it will go.

3. Connect the flue system.

Flue pipe (internal diameter): 7 125 mm

Flue system installation instructions

4. Fit the siphon.

Condensate drain pipe

Fig.7

ACondensate drain

Route the condensate drain pipe with a fall below the

anti-flooding level of the flue gas collector.

The condensate drain must be accessible for inspec-

tion.

Connection external 7: 19 mm

Neutralising system (if included)

Site the neutralising system behind the boiler and con-

nect it to the condensate drain.

Connect the neutralising system to the drainage sys-

tem.

Neutralising system installation instructions

Safety connections (cont.)

5862 417 GB

Note

Boiler water temperature sensor § is supplied in the

control unit pack.

Burner cable fA and extension together with plug lÖ

are supplied in a separate pack.

Insert the sensor and boiler water temperature sensor

§ as far as they will go into the sensor well.

!Please note

Damaged capillary tubes will result in faulty sen-

sor function.

Never kink the capillary tubes.

Fig.8

ABoiler water temperature sensor §

BBurner cables fA and lÖ

For the connections to the control unit, see the

boiler control unit installation instructions

Mounting the thermal insulation and control unit

5862 417 GB

3.9 x 20

Fig.9

Mounting the thermal insulation and control unit (cont.)

5862 417 GB

4. 2.

90°

Fig.10

ABundle the cables and secure them to the side

panel with cable ties.

Mounting the thermal insulation and control unit (cont.)

5862 417 GB

3,9 x 9,5

Fig.11

ABoiler type plate

Mounting the burner

Burner installation instructions

Commissioning and adjustment

Service instructions for boiler, burner and boiler

control unit

Mounting the thermal insulation and control unit (cont.)

5862 417 GB

Viessmann Limited

Hortonwood 30, Telford

Shropshire, TF1 7YP, GB

Telephone: +44 1952 675000

Fax: +44 1952 675040

E-mail: [email protected]

Viessmann Werke GmbH&Co KG

D-35107 Allendorf

Telephone: +49 6452 70-0

Fax: +49 6452 70-2780

www.viessmann.com

5862 417 GB Subject to technical modifications.

Viessmann VITOCROSSAL 300 Installation Instructions Manual

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