Viessmann CT3B Installation Instructions Manual Download Page 1

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Installation instructions

for contractors

VIESMANN

Vitocrossal 300
Type CT3B

, 187 to 635 kW

Gas condensing boiler

VITOCROSSAL 300

5614 451 GB

1/2014

Dispose after installation.

Summary of Contents for CT3B

Page 1: ...Installation instructions for contractors VIESMANN Vitocrossal 300 Type CT3B 187 to 635 kW Gas condensing boiler VITOCROSSAL 300 5614 451 GB 1 2014 Dispose after installation ...

Page 2: ... Regulations Observe the following when working on this system Statutory regulations regarding the prevention of accidents Statutory regulations 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 local standards a ÖNORM EN ÖVGW TR Gas ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF and...

Page 3: ...lation mat front 17 Thermal insulation mats back 18 Front fixing rails retaining bracket and cross braces 19 Rear and central fixing rails 21 Corner rails 23 Side panels and burner cables 24 Front panels 25 Boiler door 26 Back panels covers cap and boiler water temperature sensor 29 Top panels and reinforcement struts 30 Preparing the control unit installation 31 Type plate 33 Connecting the neutr...

Page 4: ... for a pur pose other than the heating up of heating water shall be deemed inappropriate Intended use presupposes that a fixed installation in conjunction with permissi ble components designed for this pur pose has been carried out Every other use will be deemed to be inappropriate Any resulting losses are excluded from the manufacturer s liabil ity Any usage beyond this must be approved by the ma...

Page 5: ... C Adjustable anti vibration feet D E Anti vibration boiler supports Note The hinge pins can be repositioned so that the boiler door opens to the left Dimensions in brackets are minimum clearances C 100 20 31 M16 D c d e d c e E Clearance dimensions 5614 451 GB ...

Page 6: ...th Adjustable anti vibration boiler feet C Permissible load kg 1200 Number pce 4 Anti vibration boiler supports Permissible load kg 1200 E 1500 D 1750 D c front number mm pce 125 2 375 2 500 2 c back number mm pce 125 2 375 2 375 2 d mm 125 30 e without load mm 22 42 e with load mm 37 Clearance dimensions cont 5614 451 GB ...

Page 7: ...he lifting gear Alter natively use the specified holes in the boiler floor B B C A A C D Lifting gear attachment points A Lifting the complete appliance B Lifting the combustion chamber module C Lifting the heat exchanger module Siting and levelling the boiler 5614 451 GB ...

Page 8: ...g easier When refitting the base support tighten the four screws with 70 Nm torque 3 3 2 F 1 Insert adjusting screws F inside the bag on the boiler support into the base rails from the top 2 Undo the timbers from the boiler base Siting and levelling the boiler cont 5614 451 GB ...

Page 9: ...on boiler supports Any unevenness in the floor should be max 1 mm to ensure the spring ele ments are evenly loaded Position the boiler supports underneath the boiler For this locate them centrally underneath the base rails When setting the boiler down less than square on a boiler support can tempo rarily be overloaded This can be pre vented by laying timbers 35 mm under the front centre and back o...

Page 10: ...s by moving hinge pins A to the r h side ensure that gasket frame B is pressed centrally onto boiler door gasket D when the boiler door is closed see detail if required align mounting brack ets C Converting the boiler door opening cont 5614 451 GB ...

Page 11: ...11 2 3 5 1 6 9 1 4 Assembly when supplied in sections 5614 451 GB ...

Page 12: ...he pack sup plied into the joint on the water side between the boiler sections and con nect the flanges with nuts and bolts 6 Secure the combustion chamber module at the bottom with M 12 x 45 screws and nuts torque 50 Nm the spacers ensure the specified gap between the modules is maintained 7 Remove all protruding sealant inside the combustion chamber Check whether sufficient sealant has been appl...

Page 13: ... 408 to 635 kW PN 6 DN 80 D Female connection for pressure lim iters R E Safety connection safety valve for 187 to 314 kW R 1 for 408 to 635 kW R 1 F Boiler water temperature sensor G Female connection for additional control equipment R H Boiler flow for 187 and 248 kW PN 6 DN 65 for 314 kW PN 6 DN 80 for 408 to 635 kW PN 6 DN 100 Connections on the heating water side 5614 451 GB ...

Page 14: ...2 Note Never connect heat consumers to the safety connector Make all necessary connections Connecting a single heating circuit Connect the heating return to boiler return 1 Connecting two heating circuits Con nect the heating circuit with the higher temperature level to boiler return 2 Connect at least 15 of the boiler heating output to boiler return 1 Close test ports that are not used for the in...

Page 15: ...incline min 3 Avoid sharp bends 2 Connect the flue system Internal 7 of the flue outlet for 187 to 314 kW 201 mm 408 to 635 kW 251 mm Flue system installation instructions Note Make all connections free of load and torque stress We recommend providing separate support for the flue system 3 Fill the siphon with water and fit it to the boiler Connections on the flue gas side cont 5614 451 GB ...

Page 16: ...twards Note on steps 2 to 4 Connect the thermal insulation mat with an overlap Note Before fitting the thermal insulation check that the serial number on the type plate matches the serial number stam ped on the boiler front panel Fitting the thermal insulation 5614 451 GB ...

Page 17: ...17 Thermal insulation mat front 1 Fitting the thermal insulation cont 5614 451 GB ...

Page 18: ...mats back 1 A 2 B A Thermal insulation mat back B Combustion chamber thermal insu lation mat Note The actual thermal insulation mats deliv ered may differ from those shown here Fitting the thermal insulation cont 5614 451 GB ...

Page 19: ...19 Front fixing rails retaining bracket and cross braces M8x16 4x A A B C B C M6x10 2x 1 2 3 M8x16 4x M8x16 4x Fitting the thermal insulation cont 5614 451 GB ...

Page 20: ...sup port using M 6x10 screws 2 Secure both retaining brackets C onto the back of the boiler with M 8x16 screws 3 Position both cross braces B onto front fixing rails A and onto retaining brackets C from the inside and secure with M 8x16 screws Note Check fixing rails A and retaining brackets C for squareness towards cross braces B possibly realign retain ing brackets vertically Fitting the thermal...

Page 21: ...0 4x E E D D 1 2 F 1 Secure both central rails D to the cross braces at the top using M 8x16 screws and to the base sup port at the bottom using M 6x10 screws 2 Secure both rear fixing rails E to the retaining brackets Fitting the thermal insulation cont 5614 451 GB ...

Page 22: ...the fixing rails at the back and front A 2 If necessary align the rear fixing rails and the cross braces so that the same clearance of side panels to the fixing rails results at the r h and l h side 3 Then tighten all rail screws Note Rear fixing rails may be secured below on the base support using M 6x10 screws 4 Unhook the two side panels again Fitting the thermal insulation cont 5614 451 GB ...

Page 23: ... the r h or the l h side for this observe the clip direction Front corner rails feature a decorative stripe Information on step 2 Hook the corner rails onto the fixing rails and secure with screws from the inside and outside For a parallel seating up to three screws B may be used per side Fitting the thermal insulation cont 5614 451 GB ...

Page 24: ... by high temperatures Prevent contact with hot compo nents Note Hook side panels into the slots provided starting at the bottom and working upwards Hook the top side panels in last the con trol unit side panel can be fitted at the front of either the l h or r h side Fitting the thermal insulation cont 5614 451 GB ...

Page 25: ... 2 A B 1 B Note on steps 1 and 2 Using strain relief B secure burner cables A to the lower front panel and the control unit Hook front panels into the fixing rail slots Fitting the thermal insulation cont 5614 451 GB ...

Page 26: ...B B Boiler door for Unit version with MatriX radiant burner Note Tighten the screws on the boiler door diagonally with 10 Nm torque Danger Leaks can result in a risk of poi soning through escaping gas Prior to commissioning check the boiler door gasket for correct seating and realign if necessary Fitting the thermal insulation cont 5614 451 GB ...

Page 27: ...27 Boiler door version for third party burners Operation with third party burners 187 to 635 kW with ventilation option C Fitting the thermal insulation cont 5614 451 GB ...

Page 28: ... Do not remove plug C 7 40 mm from the inside of the thermal insula tion block 2 Insert sight glass twin connector D into the boiler door 3 Tightly seal the vent aperture on the sight glass twin connector with the plug R G supplied otherwise there may be secondary ventilation and condensate may form Danger Leaks can result in a risk of poisoning through escaping gas Seal in plug carefully Boiler d...

Page 29: ...asher C Cap D Cover panel E Boiler water temperature sensor supplied with the control unit Note Insert the sensor and boiler water tem perature sensor into the sensor well as far as possible Please note Damaged capillaries will result in faulty sensor function Never kink the capillary tubes Fitting the thermal insulation cont 5614 451 GB ...

Page 30: ...ent struts onto cross braces C with screws Position reinforcement struts A at the front and back behind the front and back panel and secure with screws Information on step 2 Fit top panel D then position the rein forcement strut B behind top panel D and secure to cross brace C Fitting the thermal insulation cont 5614 451 GB ...

Page 31: ...aring the control unit installation 1 2 3 Note Boiler coding card included in the prod uct pack Boiler water temperature sensor is included with the control unit Fitting the thermal insulation cont 5614 451 GB ...

Page 32: ...3 2 Boiler control unit installation and service instructions Note After connecting the cables and leads secure mounting bracket fascia A to the mounting bracket Fitting the thermal insulation cont 5614 451 GB ...

Page 33: ...33 Type plate A B A Type plate B Boiler coding card Note on A Affix the type plate to an accessible side panel Fitting the thermal insulation cont 5614 451 GB ...

Page 34: ...ed size and connect it to siphon C and neutralising system A Danger Escaping flue gas can lead to a health hazard Always connect the conden sate drain with a siphon to prevent flue gas escaping Note Route the condensate drain pipe with a fall below the anti flooding level of the flue gas collector 4 Connect drain hose D to the con densate drain of the neutralising sys tem and run to drainage syste...

Page 35: ... MPa 408 to 635 kW 7 15 bar 0 715 MPa Please note Unsuitable water quality can damage the boiler shell Only fill the boiler with water that complies with the Water quality requirements see service instructions Mounting the burner For burner mounting see sepa rate burner documentation Fit the burner plate in the pack sup plied The circle of burner fixing holes and the blast tube aperture match the ...

Page 36: ...g check the boiler door gasket for correct seating and realign if required Otherwise there could be an ingress of secondary ventilation and condensate might form on the boiler door gas could also escape Fuels Natural gas and LPG in accordance with DVGW Code of Practice G 260 I and II or local regulations c Observe SVGW regulations Fitting the sight glass Fit the sight glass in the case of boiler d...

Page 37: ...ll result in a combustion efficiency of up to approx 98 Rated heating output Pressure drop on the hot gas side 1 kW Pa mbar 187 100 1 0 248 140 1 4 314 160 1 6 408 200 2 0 508 220 2 2 635 270 2 7 Commissioning and adjustment Service instructions for boiler burner and boiler control unit Danger For safe operation a minimum operating pressure of 0 5 bar 50 kPa is essential For this a minimum pressur...

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Page 40: ...hropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5614 451 GB Subject to technical modifications ...

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