Installation instructions for contractors VIESMANN Vitocrossal 300 Type CM3 Gas condensing boiler with MatriX radiant burner VITOCROSSAL 300 2/2013 Dispose after installation.
Safety instructions 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 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. These instructions are exclusively intended for qualified 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 protection 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]. a ÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and ÖVE c SEV, SUVA, SVGW, SVTI, SWKI, VKF and EKAS guideline 1942: LPG, part 2 2
Index Preparing for installation Intended use... 4 Clearance dimensions... 4 Installation sequence Siting and levelling the boiler... 5 Fitting the thermal insulation... 7 Connections on the heating water side... 9 Safety terminals... 10 Connections on the flue gas side... 11 Flue gas connection... 11 Condensate drain pipe... 11 Neutralising system (if installed)... 12 Mounting of thermal insulation and control unit... 12 Mounting the burner... 16 Commissioning and adjustment... 17 3
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 instructions. It is only designed for the heating of water that is of potable water quality. Intended usage presupposes that a fixed installation in conjunction with permissible, system-specific components has been carried out. Any usage beyond this must be approved by the manufacturer for the individual case. Incorrect usage or operation of the appliance (e.g. the appliance being opened by the system user) is prohibited and results in an exclusion of liability. Incorrect usage also occurs if the components in the heating system are modified from their intended function (e.g. if the flue gas and ventilation air paths are sealed). Commercial or industrial usage for a purpose other than heating the building or DHW does not comply with regulations. Clearance dimensions 600 450 200 4
Siting and levelling the boiler! Please note Damage to the flue outlet can result in leaks. Never lift or move the boiler at the flue outlet. Note If the boiler is sited at floor level, a suitable condensate drain (max. 50 mm above ground level) must be available inside the installation room. 2. 1. 2. ±15 5
Siting and levelling the boiler (cont.) 1. Insert the adjustable feet (included in the type plate pack) into the base rails. Note If a neutralising system is installed, wind out the adjustable feet as far as possible. 2. Using the adjustable feet, position the boiler so it is slightly inclined to the back (max. 5 mm over the boiler length). No special foundations are required. 6
Fitting the thermal insulation Note All components required for fitting the thermal insulation can be found in the thermal insulation box. 4x 3. 4x 2. 1. 7
Fitting the thermal insulation (cont.) 4. 3. 2. 1. 3. 90 4x 5. 8
Connections on the heating water side A B C D E F G H A Safety connection (safety valve and air vent valve) G 1¼ B Boiler flow PN 6 DN 50 C Female connection for control equipment R ½ D Female connection for minimum pressure switch (low water indicator) 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 connection. E Boiler return 2 PN 6 DN 40 F Boiler return 1 PN 6 DN 50 G Drain and diaphragm expansion vessel R 1 H Condensate drain R ½ 1. Thoroughly flush the heating system. 9
Connections on the heating water side (cont.) 2. Connect the heating circuits. Connecting a single heating circuit: Connect the heating return to boiler return F. Connecting two heating circuits: Connect the heating circuit with the higher temperature level to boiler return E. Connect at least 15 % of the boiler heating output to boiler return F. Safety terminals Safety equipment block installation instructions 2. Check the connections on the heating water side for leaks. 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 Permiss. operating pressure: Test pressure: 4 bar/ 0.4 MPa 5.2 bar/ 0.52 MPa Low water indicator Tests have verified that the low water indicator specified 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. 10
Connections on the flue gas side Flue gas connection 1. 1. Connect the flue outlet to the flue via the shortest possible run to the chimney, maintaining a slight incline (min. 3 ). Avoid sharp bends. 2. Insert the boiler flue connection (accessories) as far as it will go into the flue outlet. 3. Connect the flue system. Flue pipe (internal diameter): 7 125 mm 3. Flue system installation instructions 4. Mount the siphon. Condensate drain pipe Route the condensate drain pipe with a fall below the anti-flooding level of the flue gas collector. The condensate drain should be able to be inspected. Connection external 7: 19 mm A A Condensate drain 11
Connections on the flue gas side (cont.) Neutralising system (if installed) Site the neutralising system behind the boiler and connect it with the condensate drain. Connect the neutralising system to the drainage system. Installation instructions Neutralising system Mounting of thermal insulation and control unit Note Boiler water temperature sensor is supplied in the control unit pack. The 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 it will go into the sensor well. Please note! Damaged capillaries will result in faulty sensor function. Never kink the capillary tubes. 12
Mounting of thermal insulation and control unit (cont.) 2. 2. 1. A B 5. 3. 4. 4x A Boiler water temperature sensor B Burner cables fa and lö For the connections to the control unit, see the boiler control unit installation instructions 13
Mounting of thermal insulation and control unit (cont.) 2. 3.9 x 20 1. 14
Mounting of thermal insulation and control unit (cont.) 90 8. 3. A 1. 4. 2. A Bundle the cables and secure with cable ties to the side panel. 15
Mounting of thermal insulation and control unit (cont.) 3,9 x 9,5 1. 2. 4. 3. A A Boiler type plate Mounting the burner Burner installation instructions 16
Commissioning and adjustment Service instructions for boiler, burner and boiler control unit 17
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20 Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 E-mail: info-uk@viessmann.com Subject to technical modifications.