Installation Instructions for use by heating contractor Vitocrossal 300 CT3 Series Gas-fired condensing boiler Heating input: 638 to 3361 MBH 187 to 985 kW VITOCROSSAL 300 IMPORTANT Please ensure that these instructions are read and understood before commencing installation and start-up. Failure to comply with these Installation Instructions will render all warranties null and void.
Safety Vitocrossal 300, CT3 Series Installation Safety, Installation and Warranty Requirements 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).
Safety Vitocrossal 300, CT3 Series Installation Safety, Installation and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber materials 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. 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.
Table of Contents Vitocrossal 300, CT3 Series Installation Page Safety Safety, Installation and Warranty Requirements..............2 Product documentation...........................................2 Licensed professional heating contractor ...................2 Contaminated air ...................................................2 Advice to owner ....................................................2 Warranty ..............................................................2 Carbon monoxide....................
Vitocrossal 300, CT3 Series Installation Table of Contents Page Assembly Insulation Installation ................................................19 Preparing the Control Unit Installation .........................22 Insulation Installation ................................................24 Back panel, combustion chamber door and cable channel installation ..............................................24 Top panel installation ...........................................25 Observation Port Installation ...
Safety Vitocrossal 300, CT3 Series Installation Important Regulatory and Safety 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
Safety Vitocrossal 300, CT3 Series Installation Important Regulatory and Safety Requirements (continued) Codes Mechanical room 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 Note: Please carefully read this manual prior to attempting installation. Any warranty is null and void if these instructions are not followed.
General Information Vitocrossal 300, CT3 Series Installation About these 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. WARNING Warnings draw your attention to the presence of potential hazards or important product information.
Set-up Vitocrossal 300, CT3 Series Installation Mechanical Room The Vitocrossal 300, CT3 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. Do not use exhaust fans without adding additional provisions for fresh combustion air (e.g.
Set-up Vitocrossal 300, CT3 Series Installation Minimum Clearances (continued) Overall length Length Overall width Width 1 with IN 1 BS SH BTS OP SS min. 5b in. (140 mm) *1 IO CD Length of boiler pad 10 BR2 BR1 D V 12 in. (160 mm) Width 2 Width 2 with IN 2 Note: - Boiler shell, overall and foundation dimensions listed on page 29. - Minimum shipping dimensions: use “o” in the table below, and height, width 1 in the diagram above. *1 The minimum combustion head length of 5½ in.
Set-up Vitocrossal 300, CT3 Series Installation Boiler Dimensions Dimensions Boiler Model CT3- 17 22 28 37 48 57 72 89 a in. (mm) in. (mm) in. (mm) 28c (715) 11c (298) 20b (518) 28c (715) 11c (298) 20b (518) 28c (715) 11c (298) 20b (529) 62c (1594) 64c (1644) 64c (1644) 29c (751) 12c (325) 22c (577) 73 (1854) 29c (751) 14a (363) 25a (644) in.
Set-up Vitocrossal 300, CT3 Series Installation Boiler Handling, Positioning and Adjustments Please observe the minimum clearances starting on page 8. The boiler itself is mounted on a boiler pad. This boiler pad should be placed on a concrete or equivalent foundation. A recommended foundation size for each boiler model can be found on page 29. The minimum height should not be less than 4 in. (100 mm). 1. Remove wooden shipping blocks from boiler base. 2.
Assembly Vitocrossal 300, CT3 Series Installation Assembly When Supplied in Sections CAUTION Do not put any tools or any other objects into the combustion chamber. 1. Release the turnbuckles and screws M 12 on the bottom of the boiler body, pull the boiler front section out of the turnbuckles and remove it. IMPORTANT Do not use solvents. Use only clean towels and/or rags. 2. Secure supplied masking tape to all joints on the inside of the combustion chamber to prevent sealant adhering to these areas.
Boiler Connections Vitocrossal 300, CT3 Series Installation Water Side Connections 1. The existing heating system must be properly flushed, especially if the Vitocrossal 300 boiler is connected to an existing heating system in a retrofit application. 2. Connect the boiler to the system according the diagram. The sizes of all connections are given in the table on page 30. The Vitocrossal 300 boiler has two boiler return connections.
Boiler Connections Vitocrossal 300, CT3 Series Installation Hydrostatic Test Procedure Vitocrossal 300, CT3-17 to -89 All Vitocrossal 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.
Boiler Connections Vitocrossal 300, CT3 Series Installation Boiler Piping in Heating/Cooling Application Cooling unit Heating/ Cooling unit Heating/ Cooling unit Heating/ Water chiller The boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler.
Boiler Connections Vitocrossal 300, CT3 Series Installation Initial System Fill Treatment of boiler feed water should be considered in areas of known problems, such as high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system (maximum mix ratio - 50% / 50%). Please adhere to the specifications given by the antifreeze manufacturer.
Boiler Connections Vitocrossal 300, CT3 Series Installation Condensate Connection emp as t t g e Flu ll inpu u at f p tem gas ad Flue rtial lo a at p Boiler water return temperature Flue gas temperature gross of e nt at ou ns m e A ond c Amount of condensate Note: The “amount of condensate” and the “flue gas temperature gross” graphs are independent of each other. 1. Locate the neutralization unit either behind or next to the boiler. 2.
Boiler Connections/Assembly Vitocrossal 300, CT3 Series Installation Condensate Disposal All condensate disposal piping from boiler and from vent pipe system can be made from stainless steel, CPVC, or the appropriate rubber hose material as long as there is a P-trap installed in the disposal lines to avoid flue gas spillage through the condensate lines. The condensate occurring will show a reading of between 3 and 4 on the pH scale.
Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation CAUTION Do not put any tools or any other objects into the combustion chamber. All necessary parts are packed and shipped inside the insulation cartons. The installation of the insulation should only be performed once all the piping has been attached to the boiler shell and all access openings are properly closed. See following pages for installation steps. Remove combustion chamber door.
Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation (continued) 10. Attach front panel with three screws M 8 x 10 to the mounting brackets. 11. Attach the back panels with three screws M 8 x 10 to the mounting brackets. 12. Attach the short side panel to the side where the control unit is to be installed. 13. Attach both side panels with screws M 8 x 40 to the center front and bottom back panels. 14. Secure the bottom front panel with screws M 8×40 to the side panels.
Assembly Vitocrossal 300, CT3 Series Installation Preparing the Control Unit Installation 1. Attach the bottom of the mounting panel A with self-tapping screws B 3.9×9.5 to the side panel. 2. Attach the mounting panel B with two self-tapping screws B 3.9×9.5 on the back of the mounting panel (closed side oriented towards the boiler door). 3. Hook the rear of the control unit into the hooks on the rear wall of the panel. 4.
Assembly Vitocrossal 300, CT3 Series Installation Preparing the Control Unit Installation (continued) CAUTION Maximum allowable operating temperature (fixed high limit) is 99° C (210 ° F). IMPORTANT For Viessmann pre-assembled control panels, follow instructions supplied with control panel. 8. Attach the side panel with the control unit above the short side panel using four screws M 8×40. 9. Guide the boiler temperature sensor and capillary tubes to the sensor well, and push in as far as possible. 10.
Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation Back panel, combustion chamber door and cable channel installation 1. Fit the finned panels on the top left, center and bottom left together using pan head screws M 6×10. 2. Hook the left finned panels into the threads of the spacer bolts and locate them in the side panel tab. 3. Fit the finned panels on the top right, center and bottom together using pan head screws M 6×10. 4.
Assembly Vitocrossal 300, CT3 Series Installation Insulation Installation (continued) 5285 873 - 02 Top panel installation 1. Fit the back panel onto the top of the boiler, push the finned panels into the tabs and secure with four screws M 8×10 to the threaded studs. 2. Attach the round cover and cover plate with selftapping screws B 3.9×9.5 to the top of the back panel. 3. Attach the strain relief to the burner cable. 4.
Assembly Vitocrossal 300, CT3 Series Installation Observation Port Installation The combustion chamber is equipped with an observation port for the burner flame and combustionchamber. The standard equipment includes a plastic hose A, a brass nipple B, and gaskets C. The brass nipple is to be installed in the tube part of the observation port. One end of the plastic hose attaches to the nipple. The other end must be extended inside the burner housing where it is attached to the blower housing.
Assembly Vitocrossal 300, CT3 Series Installation Burner Blast Tube Insulation Packing Materials IMPORTANT The combustion chamber door opening is smaller in diameter than the burner blast tube. Do not attempt to force the burner blast tube inside the combustion chamber door. This may damage the combustion chamber door refractory. Follow these steps: 1. Measure the blast tube diameter. 2.
Assembly Vitocrossal 300, CT3 Series Installation Burner Settings CAUTION Do not exceed the maximum gas input of a particular boiler model. At the highest burner stage verify the maximum input by clocking gas meter. See instructions supplied by burner manufacturer Venting Connection Do not use any other vent material. Do not use galvanized pipe, plastic pipe and/or B-vent/Lvent chimney liners of any kind.
Start-Up Vitocrossal 300, CT3 Series Installation Initial Start-Up Pressure drop (primary circuit) The Vitocrossal 300 boiler is only suitable for heating systems with pumped heating water. For start-up and adjustments, see the service instructions for boiler, burner and boiler control unit CAUTION Pressure drop Do not fire the burner unless boiler and heating system are properly filled with water and purged of any air.
Appendix Vitocrossal 300, CT3 Series Installation Technical Data CT3- Input MBH (kW) MBH (kW) MBH MBH MBH (kW) 638 846 1071 1389 1726 2160 2702 3361 (187) (248) (314) (407) (506) (633) (792) (985) 626 827 1044 1350 1675 2094 2616 3252 (183) (242) (306) (396) (491) (614) (767) (953) 98.3 97.8 97.4 97.2 97.1 96.9 96.8 96.7 98.1 97.7 97.4 97.2 97.1 96.9 96.8 96.7 554 734 930 1206 1502 1879 2351 2924 (162.3) (215.3) (272.6) (353.3) (440.2) (550.7) (689.0) (857.
Appendix Vitocrossal 300, CT3 Series Installation Technical Data (continued) Boiler Model Weight boiler shell Overall weight complete with insul. and control (w/o burner) Boiler water content Heat exchanger surface water-cooled Max. operating temperature Max.
5285 873 - 02 Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper.
