Viessmann VITOCROSSAL 300 Bedienungsanleitung

Installation instructions

for contractors

VIESMANN

Vitocrossal 300

Type CR3 and CR37

Gas fired condensing boiler

Rated output 787 and 978 kW

VITOCROSSAL 300

5862 299 GB 11/2009 Dispose after installation.

Please follow these safety instructions closely to prevent accidents and mate-

rial losses.

Safety instructions explained

Danger

This symbol warns against the

risk of injury.

!Please note

This symbol warns against the

risk of material losses and envi-

ronmental pollution.

Note

Details identified by the word "Note" con-

tain additional information.

Target group

These instructions are exclusively

designed for qualified personnel.

■ Work on gas appliances must only be

carried out by a qualified gas fitter.

■ Work on electrical equipment must

only be carried out by a qualified elec-

trician.

Regulations

Observe the following when working on

this system

■ all legal instructions regarding the pre-

vention of accidents,

■ all legal instructions regarding envi-

ronmental protection,

■ the Code of Practice of relevant trade

associations,

■ all current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

Working on the system

■ Isolate the system from the power sup-

ply and check that it is no longer 'live',

e.g. by removing a separate fuse or by

means of a mains isolator.

■ Safeguard the system against unau-

thorised reconnection.

■ When using gas as fuel, also close the

main gas shut-off valve and safeguard

against unauthorised reopening.

Safety instructions

5862 299 GB

Preparing for installation................................................................................... 4

Installation sequence

Boiler positioning and levelling............................................................................. 6

■Installation with anti-vibration boiler supports................................................... 6

■Installation without anti-vibration boiler supports.............................................. 6

Assembly when supplied in sections.................................................................... 7

Fitting the feet to the heat exchanger module...................................................... 9

Flue gas connection............................................................................................. 9

Fitting the thermal insulation................................................................................ 10

■ Boiler body thermal insulation........................................................................... 10

■ Front thermal insulation.................................................................................... 11

■ Front rails.......................................................................................................... 11

■ Back rails.......................................................................................................... 12

■ Centre rails........................................................................................................ 13

■ Routing burner cables....................................................................................... 14

■ Side panels and back rails................................................................................ 14

■ Rear thermal insulation..................................................................................... 15

■ Rear panels....................................................................................................... 16

■ Front panels...................................................................................................... 17

■ Preparing the control unit installation................................................................ 18

■ Fitting the top panels......................................................................................... 20

Connecting the heating water side....................................................................... 21

Making the safety connections ............................................................................ 22

Stench trap installation......................................................................................... 23

Connection of the neutralising system................................................................. 24

Burner installation................................................................................................. 24

Fuels..................................................................................................................... 24

Installing the combustion chamber sight glass..................................................... 25

Adjust burner........................................................................................................ 25

Commissioning and adjustment........................................................................... 25

Index

5862 299 GB

Clearance dimensions

Note

You can reposition the hinge bolts so

that the door opens to the left.

(300)

200 (100)

500 (50)

400

500 (50)

ABb

ABoiler

BBurner

CAnti-vibration boiler supports

Dimensions in brackets are minimum

clearances.

Preparing for installation

5862 299 GB

Rated output kW 787 978

amm 1500 1500

bmm Observe the burner

length

Anti-vibration boiler supports

Permissible load kg 3000

c (front) / number mm/pce 750/2

c (back) / number mm/pce 750/2

dmm 30

e (without stress) mm 42

e (stressed) mm 37

Preparing for installation (cont.)

5862 299 GB

Installation with anti-vibration boiler supports

Ensure the boiler foundation is level.

Position the boiler onto the anti-vibration

boiler supports. Continue on page 7

or 9.

Installation without anti-vibration boiler supports

1. Insert the adjustable screws into the

bottom rails. Position a plate, e.g. a

flat steel strip, underneath each

adjusting screw to evenly distribute

the weight.

2. Level the boiler. Special foundations

are not required.

Boiler positioning and levelling

5862 299 GB

AHeat exchanger module

BCombustion chamber module

CSealant (in the pack supplied)

DGaskets (in the pack supplied)

Assembly when supplied in sections

5862 299 GB

!Please note

Scratches on parts that are in

contact with flue gas can lead to

corrosion.

Never put tools or other objects

into the combustion chamber.

1. Apply sufficient (2-3 tubes) sealing

material (part of the standard deliv-

ery) evenly to the annular groove of

the combustion chamber and heat

exchanger modules.

2. Position the heat exchanger module

on the combustion chamber module.

Note

Use the lifting eye to lift the heat

exchanger module.

3. Insert gaskets (in the pack supplied)

between the upper and lower flanges

and tighten screws and nuts diago-

nally.

4. Fit and tighten the M16 nuts by

hand.

5. Check that there is sufficient sealant

all around the sealing face of the

combustion chamber.

Close any gaps between the com-

bustion chamber module and the

heat exchanger module with seal-

ant.

Danger

Solvent vapours from the

sealant can cause irritation of

the respiratory system.

Ensure adequate ventilation

in the combustion chamber or

wear breathing equipment.

Note

Allow 4 hours for the sealant to dry

before commissioning.

6. Remove excess sealant (out of the

combustion chamber) from the heat

exchanger module.

Assembly when supplied in sections (cont.)

5862 299 GB

1. Wind the anti-vibration feet in as far

as possible.

2. Secure the feet with two screws each

to the l.h. and r.h. side of the heat

exchanger using the top holes.

3. Wind out the feet until the heat

exchanger module is sufficiently sup-

ported.

Flue gas connection

Ø 10 mm

2-3 x D

Flue gas system installation

instructions

1. Connect the flue outlet via the short-

est possible run to the chimney stack,

maintaining a slight incline.

Avoid sharp bends.

Flue internal 7: 301 mm

2. Create a resealable test port A.

3. Seal the flue (all flue connections

must be pressure-tight).

Fitting the feet to the heat exchanger module

5862 299 GB

Boiler body thermal insulation

Note

Before fitting the thermal insulation,

check the serial number on the type plate

and compare it with the serial number

stamped on the front of the boiler.

If the boiler is supplied in sections,two

type plates will be included.

Fitting the thermal insulation

5862 299 GB

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