Viessmann Boiler Documentation (Single Fuel CA3B) Vitocrossal 300, CA3B Installation Instructions
Annonce
Annonce
Installation Instructions
for use by heating contractor
Vitocrossal 300
CA3B Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0
Gas condensing boiler with cylinder burners
Heating input: 2500 to 6000 MBH
(733 to 1758 kW)
VITOCROSSAL 300
H
5814 894 - 07 01/2019
Product may not be exactly as shown
IMPORTANT
Read and save these instructions for future reference.
Please file in Service Binder
2
Safety
Vitocrossal 300 CA3B Series 2.5 to 6.0 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).
Product documentation
Read all applicable documentation before commencing installation. Store documentation near boiler in a
readily accessible location for reference in the future by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.
Carbon monoxide
Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon
For information pertaining to the proper installation, adjustment, service and maintenance of this equipment to avoid formation of carbon monoxide, please see subsection entitled
“Mechanical room” and “Venting requirements” in this manual.
Licensed professional heating contractor
The installation, adjustment, service and maintenance of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Fresh air
This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist.
For information pertaining to the fresh air requirements of this product, please see subsection entitled
“Mechanical room” in this manual.
Contaminated air
Air contaminated by chemicals can cause by-products in the combustion process, which are poisonous to inhabitants and destructive to
For a listing of chemicals which cannot be stored in or near the
boiler room, please see subsection entitled “Mechanical room” in this
manual.
equipment.
Equipment venting
Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.
For information pertaining to
venting please see section entitled “Venting
All products of combustion must be safely vented to the outdoors.
Advice to owner
Once the installation work is complete, the heating contractor must familiarize the system operator/ ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the
heating season begins.
WARNING
Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained in this manual.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Safety, Installation and Warranty Requirements
(continued)
Safety
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.
First aid measures
- If eye contact occurs, flush eyes with water to remove
dust. If symptoms persist, seek medical attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
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.
Suppliers of ceramic fiber products recommend the following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.
- Eye irritation: If eyes become irritated, flush immediately
with large amounts of lukewarm water for at least 15
minutes. Eyelids should be held away from the eyeball
to ensure thorough rinsing. Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and cold
water (as warm or hot water may worsen the irritation).
Using a skin cream or lotion after washing may be
helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.
Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause serious injury or loss of life and which are known to the State of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.
Codes
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 Codes for Gas Burning
Appliances for Canada. For U.S. installations, use the
National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes.
In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S., use the National Electrical Code ANSI/
NFPA 70.
The heating contractor must also comply with the Standard for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the authority having jurisdiction.
Mechanical room
Ensure the mechanical room complies with the requirements of this manual.
In addition, see section entitled “Mechanical Room” on page 8 in this manual.
Viessmann recommends installation of an additional electrical disconnect switch and a fuel shut-off valve (if possible) outside the mechanical room or enclosed area of installation.
The maximum room temperature of the mechanical room where the boiler is located must not exceed 104°F (40°C).
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4
Table of Contents
Safety
General Information
Preinstallation
Installation
System Layout
Venting
Venting Options - Stainless Steel/PP(s)
Vitocrossal 300 CA3B Series8 2.5 to 6.0 Installation
Page
Safety, Installation and Warranty Requirements ............
2
Important Regulatory and Installation Requirements ........
5
About these Installation Instructions .............................
7
Product Information ....................................................
7
Mechanical Room .......................................................
8
For Retrofit Applications ..............................................
8
Recommended Minimum Service Clearance ...................
9
Unpacking the Boiler .................................................
10
Placement of Boiler ...................................................
10
Reducing Boiler Height - if required ............................
11
Placing the Boiler .....................................................
14
Removing the Boiler Panels........................................
14
Boiler Connections ....................................................
15
Electrical Connections............................................
18
EA1 Extension .....................................................
33
EA1 Extension Additional Functionality .....................
35
Integrating the Control into the LON ...........................
36
Making the LON Connection ......................................
37
Installing the Boiler Panels .........................................
38
Connecting Flue Gas Pipe ..........................................
39
Connecting Neutralization System ..............................
40
Condensate Connection ............................................
41
Gas Connections ......................................................
42
Initial System Fill General Requirements ....................
45
General ...................................................................
46
System Layout 1 ..................................................
47
System Layout 2 ..................................................
48
Boiler Piping in Heating/Cooling Application .................
49
General Venting Information ......................................
50
Connecting Combustion Air Intake for Direct Vent ........
53
Additional Requirements for Stainless Steel
Vent Pipe Material ....................................................
53
Requirement for UL/ULC Listed Rigid SS/PP(s)
Vent Pipe Material ....................................................
54
Vent Requirements ................................................
55
Direct Venting (Two Pipe System) ..............................
56
Side Wall Venting .................................................
57
Component Installation Guide ..................................
57
Elbow - Equivalent Length ......................................
57
Vent Termination Location Requirements - Vertical .......
58
Installation of Support System - PP(s) .........................
58
Two Pipe System - Vertical Exhaust/
Vertical Air Intake ....................................................
59
Two Pipe System - Horizontal Exhaust/
Horizontal Air Intake .................................................
61
Two Pipe System - Vertical/Horizontal Installations .......
62
Individual Burner Intake Ducting ..............................
63
Single Pipe System - Vertical Exhaust/
Room Air Dependant .................................................
64
Single Pipe System - Horizontal Exhaust/
Room Air Dependant .................................................
65
Multiple Boiler Installations .....................................
66
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Important Regulatory and Installation Requirements
General Information
(b)
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 than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professional for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half ( b ) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
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General Information
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Important Regulatory and Installation Requirements
(continued)
For Polypropylene venting systems only
Minimum and maximum wall thickness through which the horizontal vent-air intake termination may be installed:
Minimum: 1 in. (25.4 mm)
Maximum: 30 in. (762 mm)
Vent-air intake system must be properly installed and sealed.
If PP(s) venting system passes through an unheated space, such as an attic, it must be insulated.
The insulation must have an R value sufficient to prevent freezing of the condensate. Armaflex insulation with b in. thickness and higher can be used.
Venting clearance to combustibles (Stainless Steel /
Polypropylene)
As per vent manufacturer’s requirements.
WARNING
Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury, or loss of life. Flue gases may contain deadly carbon monoxide.
CAUTION
Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (e.g. aluminum sheeting) may be required to prevent staining or deterioration. The protective material should be attached and sealed (if necessary) to the building before attaching the vent termination. It is strongly recommended to install the vent termination on the leeward side of the building.
FM (Factory Mutual) Global
FM Global (formerly Factory Mutual Systems) participates on the ASME CSD-1 Committee and has aligned their requirements with those of ASME CSD-1. FM Gobal will accept a standard UL or ETL Listed Boiler complying with
ASME CSD-1 up to 2,500,000 BTU.
From 2.5 to 12.5 Million BTU, they still align with the
ASME CSD-1 standard but may require additional FM
Global approved components (field supplied).
Note: The local GE GAP or FM Global Inspectors have the right to request additional safeguards for unusual risks, but the ASME CSD-1 standard as outlined is normally accepted as meeting their requirements.
Working on the equipment
The installation, adjustment, service, and maintenance of this boiler must be performed by a licensed professional heating contractor who is qualified and experienced in the installation, service and maintenance of hot water boilers.
There are no user serviceable parts on the boiler, burners or control.
Note: The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. This includes low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc .
Ensure main power supply to equipment, the heating system and all external controls have been deactivated.
Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.
ASME CSD-1 Standard
The ASME CSD-1 standard is published by ASME
(American Society of Mechanical Engineers) and covers the requirements for the assembly, installation, maintenance, and operation of the controls and safety devices on automatically operated boilers directly fired with gas, oil, gas-oil, or electricity. The gas valve of this boiler meets the requirements as set forth in the ASME CSD-1 standard.
IRI (Industrial Risk Insurers)
IRI (Industrial Risk Insurers) requirements for boilers have been replaced by GE Global Asset Protection (GAP)
Services requirements, please refer to section describing
GE GAP requirements.
GE GAP (Global Asset Protection)
GE GAP Services publishes GE GAP Guidelines for various risks including boiler combustion codes and standards.
In many cases, they adopt other existing nationally recognized standards. GE GAP Guidelines replace and eliminate the former IRI requirements. GE GAP requires compliance with ASME CSD-1 up to 12,500,000 BTU.
Technical literature
Literature for the Vitocrossal 300, CA3B boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instruction
- Instructions of other products utilized and installed
- Installation codes mentioned in this manual and as
locally applicable
Note: Leave all literature at the installation site and
advise the system operator/ultimate owner where
the literature can be found. Contact Viessmann for
This product comes with several safety instruction
labels attached. Do not remove!
Contact Viessmann immediately if replacement
labels are required.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
About these Instructions
General Information
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.
Warnings draw your attention to the presence of
potential hazards or important product information.
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/ property damage.
Cautions draw your attention to the presence of
potential hazards or important product information.
IMPORTANT
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
Product Information
High efficiency gas-fired hot water condensing boiler. For operation with modulating boiler water temperatures in closed loop, forced circulation hot water heating systems.
The Vitocrossal 300, CA3B boilers are CSA certified with
Viessmann burners which must be used in conjunction with this boiler series. The proper burner size must be verified and the burners are factory adjusted so that the maximum input of the appropriate boiler size is always observed.
The gas burners must always be installed according to the instructions provided by the burner manufacturer.
The boiler model selected should be based on an accurate heat loss calculation of the building. The boiler selected must be compatible with the connected radiation.
The Vitocrossal 300, CA3B boiler is suitable for a maximum operating pressure of 160 psig and a maximum boiler water temperature of 210°F (99°C).
This boiler does not require a flow switch.
WARNING
Exposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.
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General Information
Mechanical Room
For Retrofit Applications
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
The Vitocrossal 300, CA3B 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.
Install boiler on flooring capable of supporting the weight of the boiler filled with water.
Do not use exhaust fans without adding additional provisions for fresh combustion air (e.g. fresh air fan) in the boiler room and do not install the Vitocrossal 300,
CA3B boiler in rooms with refrigeration equipment. This boiler requires uncontaminated air for safe operation - do not install where chemicals are stored.
Do not operate when air is polluted with solvents,
chlorides, fluorides, cleaning agents or particulates of any kind.
Prevent very dusty conditions (if necessary install a field supplied combustion air intake filter).
Refer to page 56 for additional information.
Prevent high levels of humidity.
Prevent freezing and ensure good ventilation.
Otherwise, the system may suffer faults and damage which is not covered under warranty.
Before boiler is connected to piping/heating system,
(which has been previously in service) the piping must be flushed with city pressure water (50-60 psi) to remove sludge and other contaminates.
Failure to flush out the heating system piping may result in restricted flow and/or deposits resulting in boiler failure.
This failure is not covered under warranty. Installation of magnetic filtration is recommended.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Recommended Minimum Service Clearances
CA3B 2.5, 3.0, 3.5 and 4.0
CA3B 5.0 and 6.0
Preinstallation
To enable convenient installation and maintenance, observe the stated recommended minimum service clearance dimensions.
3.0
3.5
4.0
5.0
CA3B
Model a in.
(mm) b *
1 in.
(mm) c in.
(mm)
Top clearance
2.5
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
6.0
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
31 b
(800)
31 b
(800)
29 b
(750)
31 b
(800)
Mechanical room
Avoid air contamination by halogenated hydrocarbons
(e.g. as in sprays, paints, solvents and cleaning agents)
Avoid very dusty conditions
Avoid high levels of humidity
Protect against frost and ensure good ventilation, otherwise the system may suffer faults and damage.
In rooms where air contamination from halogenated hydrocarbons is to be expected, operate the boiler using only direct vent (sealed combustion) operation
only.
Minimum clearances to combustibles
CA3B
Model
Top
Sides
Flue
2.5
3.0
3.5
0
0
4.0
5.0
6.0
per vent manufacturer’s specifications
Front
Floor
0 combustible
Legend
A Boiler
*
1 Clearance for vent pipe installation.
B Boiler combustion air intake grill
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10
Preinstallation
Unpacking the Boiler
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Note: The boiler can be lifted by crane only while it is still
packed.
1. Remove plastic covering.
2. Dismantle the wooden packaging framework.
3. Lift the boiler form the packaging platform using a pallet or forklift truck. Use fork extensions. Observe
Boiler weight (without water) lb.
(kg)
4233
(1920)
4233
(1920)
4696
(3130)
4806
(2180)
6262
(2840)
6894
(3127)
Placement of Boiler
Lifting the boiler
1. There is a boiler lifting location for the forks of a lift
truck or forklift on the right and left side of the boiler.
2. There is a boiler lifting location for the forks of a lift truck or forklift on the front of the boiler.
IMPORTANT
When lifting the boiler from the side ensure the forks of the lift truck or forklift are centered. Refer to the located on the side of the boiler.
mark
It is essential to use appropriate lifting devices certified for lifting to a minimum of the boiler weight.
WARNING
If flue gas collector is damaged leakage may occur.
Do not lift boiler at the flue gas collector.
Positioning boiler
The boiler must be placed on a foundation.
A minimum height of 4 in. (100 mm) is required in order to allow for the condensate siphon connection.
Without seismic feet
CA3B
Model a in.
(mm)
2.5
74 c
(1900)
3.0
74 c
(1900) b in.
(mm)
34
(860)
34
(860)
3.5
4.0
5.0
6.0
82 c
(2100)
39 b
(1000)
82 c
(2100)
39 b
(1000)
114 a
(2900)
39 b
(1000)
114 a
(2900)
39 b
(1000)
With seismic feet
CA3B
Model
2.5
a in.
(mm)
85 a
(2165)
b in.
(mm)
48 a
(1225)
3.0
85 a
(2165)
48 a
(1225)
3.5
4.0
5.0
6.0
94
(2388)
53
(1346)
94
(2388)
53
(1346)
125
(3175)
53
(1346)
125
(3175)
53
(1346)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Reducing Boiler Height
- if required
Preinstallation
MMBTU
Total height
(does not include boiler pad or seismic feet)
Height
(without upper panels, upper frame components, burner and piping)
2.5–3.0
78 c in.
(2000 mm)
64 a in.
(1630 mm)
3.5–4.0
83 7/8 in.
(2131 mm)
68 in.
(1728 mm)
5.0–6.0
83 7/8 in.
(2131 mm)
77 c in.
(1974 mm)
Reducing the overall height of the boiler during placement
The overall boiler height can be reduced for placement.
Panels, frame components with piping and burner can be removed.
WARNING
Contact with hot surfaces can lead to burn injuries.
Undertake work on the burner only when the system is cold.
WARNING
Escaping gas leads to a risk of explosion.
Close the gas shut-off valve.
IMPORTANT
Disconnect power and close the gas shut-off valve to ensure system is shut down during any service work on the burner.
11
Preinstallation
Reducing Boiler Height
(continued) (continued)
CA3B 2.5 to 4.0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
1. Remove the 4 screws from the right side of the top panels.
2. Lift and remove the top right side panels.
3. Slide the top panels toward the right side and remove.
4. Lift and remove the top left side panels.
5. Remove the nut and bolt from each side of the lower
portion of the upper frame profiles.
6. Remove the upper frame profiles.
7. Remove the top front panel.
8. Remove the rear top panel.
9. Reinstall upper frame profiles and front and rear panels
once positioning is completed.
12
CA3B 5.0 and 6.0
1. Remove the 6 screws from the right side of the top panels.
2. Lift and remove the top right side panels.
3. Slide the top panels toward the right side and remove.
4. Lift and remove the top left side panels.
5. Remove the nut and bolt from each side of the lower
portion of the upper frame profiles.
6. Remove the upper frame profiles.
7. Remove the top front panel.
8. Remove the rear top panel.
9. Reinstall upper frame profiles and front and rear panels
once positioning is completed.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Reducing Boiler Height
- if required
(continued)
Preinstallation
Detach upper burner section
1. Disconnect the burner gas line.
2. Disconnect the connector from the burner control unit.
3. Pull off the ignition electrode connectors.
4. Remove 2 screws on the ignition electrode block.
Lift the electrode block upwards to remove.
5. Remove 6 nuts.
6. Remove burner.
WARNING
The burner, weighing up to 88 lb. (40 kg) may cause injury if not handled correctly. Lift the burner’s upper section using suitable tools, e.g. lifting mechanism.
IMPORTANT
A lifting mechanism is required to remove the burner.
Secure lifting mechanism chains at 3 points A on the frame of the upper burner section.
1. Lift upper burner section with lifting mechanism.
2. Place upper burner section aside.
Refer to the lifting device Instructions.
Refer to the Service Instructions for addition information when reinstalling the burner.
13
Installation
Placing the Boiler
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Note: It is recommended that the levelling bolts included with the boiler are used when installing the boiler
on uneven surfaces.
Once removed from the wooden shipping pallet from the boiler base. Remove the 4 leveling bolts A from boiler’s accessory package and install into the four corners of the boiler base.
Note: When using seismic brackets B (optional accessory) do not install levelling bolts.
Refer to the Seismic bracket Installation
Instructions when using the optional seismic mounts.
It is recommended to place a flat piece of steel plate under each leveling bolt for better weight distribution and adjustment.
3. Level the boiler, by adjusting the floor levelling bolts.
14
Removing the Boiler Panels
1. Remove all the screws from the right side of the top panels.
2. Lift and remove all the top right side panels.
3. Slide all the top panels toward the right side and remove.
4. Lift and remove all the top left side panels.
5. Lift and remove all the bottom left side panels.
6. Tilt forward, lift and remove lower front panel.
7. Remove the 6 screws from the lower front cover plate and remove plate.
8. Lift and remove the top front panel (for CA3B 5.0 and only).
9. Remove the 4 screws from the top front cover plate and remove plate (for CA3B 5.0 and 6.0 only).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Boiler Connections
Installation
IMPORTANT
The Vitocrossal 300, CA3B boiler is only suited for hot water heating. Do not install a 4-way mixing valve.
Note: Make all connections free of load and torque stresses.
The heating system must be properly flushed, especially if the Vitocrossal 300, CA3B boiler is connected to an existing heating system in a retrofit application.
Refer to page 8 for details.
Connect the system to the boiler according to the diagram shown on page 47.
Note: All connections which are not being utilized for water connections or for controls must be properly closed.
The supplied air vent and pressure relief valve must be installed on the supply header of the boiler - the alternate pressure relief valve location may be in the boiler supply line. The piping to the precharged expansion tank, as well as any automatic feed water required, must be connected to the boiler return. Boiler pump shall be installed on return pipe, pumping water into the boiler.
The supplied low water cut-off should be installed directly on the safety header of the boiler or may be installed in the boiler piping above the pressure vessel.
Note: Piping diagrams for specific system layouts are available. Please enquire with your local Viessmann sales representative.
All Vitocrossal 300 boilers are hydrostatically factory tested to ASME requirements.
Safety Header
CAUTION
Do not connect heating system to safety header.
1. Locate safety header on the main supply header.
Max. allowable working pressure (MAWP): ... 160 psi (11 bar)
Min. water pressure: ............................... 8 psi (0.5 bar)
Note: The minimum water pressure is necessary for safe operation.
Note: All boilers must have a pressure relief valve.
WARNING
Exposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.
Note: Make all connections free of load and torque stresses.
Legend
A Boiler supply
B Temperature/pressure gauge
C Pressure relief valve
D Boiler return
E Drain valve
F Precharged expansion tank
G Automatic fill
H Condensing water drain
I Flue gas test port
15
Installation
Boiler Connections
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Safety Header (continued)
16
Legend
1 Boiler return: (ANSI 4 in. for models 2.5, 3.0, 3.5,
4.0 and 5.0 and ANSI 6 in. for model 6.0) *1
2 Boiler supply: (ANSI 4 in. for models 2.5, 3.0, 3.5,
4.0 and 5.0 and ANSI 6 in. for model 6.0) *1
3 Safety header: (Pressure relief valve, low water cutoff, automatic air vent and temperature/pressure gauge)
A Hex bushing b in. x e in.
B Air vent with shut-off base
C Plug b in.
D Reducer 2 in. to 1 in. for models 2.5 and 3.0,
2 in. to 1 a in. for models 3.5 and 4.0,
2 in. to 1 b in. for models 5.0 and 6.0
E Nipple 1 in. for models 2.5 and 3.0
1 a in. for models 3.5 and 4.0
1 b in. for models 5.0 and 6.0
F Pressure relief valve, 75 psi *2
G Low water cutoff
H Temperature/pressure gauge
4 Drains:
I Nipple 1 b in. x 10 in.
J Reducer 1 b in. x c in.
K Sediment faucet c in.
5 Gas line fittings:
L Gas gas shut-off valve,
2 b in. for models 2.5, 3.0, 3.5 and 4.0, 3 in. for models 5.0 and 6.0
*1 Counter flanges, gaskets and hardware (field supplied)
*2 Alternate pressure relief valves are available depending on operating pressure requirements. Contact your local
Viessmann sales representative for details.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Boiler Connections
(continued)
Installation
Boiler water drain valve
Using a water drain valve facilitates the drainage of a heat exchanger. The supplied drain valve must be installed in each boiler section before filling.
1. Locate and remove drain plug for each boiler section.
2. Install drain valve assembly for each boiler section as shown.
Legend
A 1 b in.
x 10 in. nipple
B 1 b in. to c in. reducer
C c in. sediment faucet
17
Installation
Electrical Connections
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
18
Legend
(e.g. boiler power supply)
(e.g. sensor cables)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Connection overview for CA3B 2.5 to 4.0
Installation
Legend
A Supply temperature sensors heating circuits M2/M3
B External LON participants (i.e. Vitotronic 200-H)
C Low voltage/sensor connections
D Boiler power supply connection
E Pumps/mixing valve connections
F Disconnect switch with lockout provision
G EA1 extension
19
Installation
Electrical Connections
(continued)
Connection overview for CA3B 5.0 and 6.0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
20
Legend
A Supply temperature sensors heating circuits M2/M3
B External LON participants (i.e. Vitotronic 200-H)
C Low voltage/sensor connections
D Boiler power supply connection
E Pumps/mixing valve connections
F Internal disconnect switch (with lockout provision)
G EA1 extension
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Heating circuit - extension connection
Installation
Legend
? M2/M3 supply temperature sensor
X11
Extra-low voltage printed circuit board connections
! Outdoor temperature sensor
§ / ?
Common supply temperature sensor
% A Tank temperature sensor
% B system (accessory) aJ B
(accessory) aVD External connection aVH External connection
Low voltage connections at the system and boiler section 1 controller
Outdoor temperature sensor
Fitting location for outdoor temperature sensor
H
North or north-westerly wall, 6 to 8 ft (2 to 2.5 m) above ground level; in multi storey buildings, in the upper half of the second floor.
H
Not above windows, doors or ventilation outlets.
H
Not immediately below balconies or gutters.
H
Never paint over.
Outdoor temperature sensor connection
2 wire cable, 18 AWG for a maximum length of 115 ft.
(35 m).
Common supply temperature sensor
H
For single boilers systems or multi-boiler systems using external cascade control, mount the common supply temperature sensor on the supply piping near the boiler.
H
For multi-boiler systems using integrated cascade capabilities, mount the common supply sensor on the supply piping common to all boilers.
Refer to the system layouts on page 47.
21
Installation
Electrical Connections
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Note: The DIN terminals can be used with solid, stranded or stranded with ferrule termination. The ferrule will help to prevent ‘fraying’ of the stranded wires
during
Specific connections are detailed throughout the manual, refer to the appropriate section prior to making any connections.
Accessory connections
The accessory terminals include a L, N terminal connection orientated at the top of the rail which is pre-wired to the cable harness set. The L, N, G terminals orientated at the bottom of the DIN rail for accessory connection is used to for connections to external equipment (ie. Pumps, mixing valves, etc). The individual terminals are a ‘push-in’ design, meaning to install or release a wire, the orange button must be pushed in (refer to image below for location of orange buttons denoted by B ), prior to installing or removing any wires to the terminal.
Top
22
Bottom
Legend
A DIN terminal accessory connections
B Push-in button
C DIN rail (typical)
D Terminal insertion point
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Top
Installation
Main power supply connections
The main power supply terminals are a push-in design. To install or release a wire from the terminal push the orange button B .
The main power supply terminal will accept only one connection L, N or G. Each terminal is designated by color:
Grey - Line
Blue - Neutral
Green / Yellow - Ground
Refer to page 32 for power supply connection details.
Bottom
Legend
B Push-in button
C DIN rail (typical)
D Terminal insertion point
Internal control fuse F3
When fuse F3 requires replacement, (refer to the separate wiring diagram) the fuse can be accessed as shown.
1. Flip down the front portion of the DIN rail mounted fuse block.
2. Flip down the front side cover of the DIN rail mounted fuse block.
3. Replace fuse.
4. Return the DIN rail mounted fuse block back to the position.
Refer to wiring schematic for fuse F3 location.
23
Installation
Electrical Connections
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
24
Legend sÖ A1 Heating circuit pump A1 sÖ M2 Heating circuit pump M2 sÖ M3 Heating circuit pump M3 sA sK sL gÖ
Circulation pump for tank heating
DHW recirculation pump
Boiler circuit pump
Central fault message gS 3-way mixing valve gS M2/M3 Mixing valve motor 120 V~
A 120V Power supply for accessories
B On-site safety equipment
C On-site indoor air damper
D Feedback contact
Note: To connect feedback contact D , remove jumper
25 L/26 L (factory set condition).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Connecting Pumps
Installation
Rated voltage
Rated current Max.
120V~
2A~
Note: Maximum output 6FLA shared between all
120V outputs.
Pumps 120V
Available pump connections sÖ A1 Heating circuit 1 pump sÖ M2 Heating circuit 2 pump sÖ M3 Heating circuit 3 pump sA DHW sK DHW recirculation pump sL Boiler pump/system pump sA sK sL
Available connections
Connections on extension for heating circuit with mixing valve HC2/M2, HC3/M3
Plug sÖ sÖ
M2
M3
Terminal
5 L, N, G
6 L, N, G
Component
Heating circuit pump
Heating circuit pump
Connections on the PCB 120V~ sÖ A1 9 L, N, G
8 L, N, G
7 L, N, G
10 L, N, G
Heating circuit pump for heating circuit A1 or
Primary pump, tank loading system
DHW pump
DHW recirculation pump boiler pump, system pump
25
26
Installation
Electrical Connections
(continued)
Connecting Pumps (continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
120V pumps with an amperage draw of <2FLA
Legend
A DIN rail (located in the junction box)
B Pump
120V pumps with an amperage draw of >2FLA
Contactor specification 120VAC 1A
Legend
A DIN rail (located in the junction box)
B Contactor/relay (field supplied)
C Pump
D Power supply w/disconnect and protection
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Installation
Connecting Pumps (continued)
240V pumps
Contactor specification 120VAC 1A
Legend
A DIN rail (located in the junction box)
B Contactor/relay (field supplied)
C Pump
D Power supply w/disconnect and protection
208/460/575V 3 phase pumps
Contactor specification 120VAC 1A
Legend
A DIN rail (located in the junction box)
B Contactor/relay (field supplied)
C Pump
D Power supply w/disconnect and protection
27
28
Installation
Electrical Connections
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Connecting a Central Fault Message Facility
Plug gÖ (terminal 11 - L, N, G)
Rated voltage
Rated current Max.
120V~
2A~
Note: Maximum output 6 FLA shared between all 120V
outputs.
Connecting Mixing Valve Actuators
1. Disconnect power to control.
2. Connect valve actuator wires to the DIN terminals as shown (based on desired functionality).
Available connections gS M2 For heating circuit 2 gS M3 For heating circuit 3
Rated voltage
Rated current Max.
120V~
0.1A~/ output
Motor runtime for
3-way mixing valve: 10 to 255 sec, adjustable via coding addresses “c3” in the heating circuit
2 group and “c3” in the heating circuit 3 group.
Plug
52M2
52M3
DIN terminals
1 (L, N)
2 (L)
3 (L, N)
4 (L)
Legend
A DIN Rail (in junction box)
B 120V Valve Actuator
C Valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
Installation
Connecting Mixing Valve Actuators (continued)
1. Disconnect power to control.
2. Remove plug connect gS from cables BK1, BK2 and
BK3 of the 24V valve adaptor.
3. Connect BK1, BK2 and BK3 to DIN terminals for desired valve application. Refer to the chart below.
4. Connect black wire D of the mixing valve adaptor to an available terminal 12-14 on the DIN rail.
5. Connect valve actuator wires to the adaptor terminals as shown in image above.
Refer to the mixing valve adaptor Installation
Instructions for additional information.
Plug gS gS
M2
M3
DIN terminals
1 (L, N)
2 (L)
3 (L, N)
4 (L)
Legend
A 24V Mixing Valve Adaptor
B Cable to plug gS
C Connecting cable to 12, 13 or 14
D 24V Mixing Valve Motor
24V Valve Adaptor
Rated voltage:
Rated current:
24VAC max. 0.15 FLA
Available connections gS M2 For heating circuit 2 gS M3 For heating circuit 3
Motor runtime for
3-way mixing valve: 10 to 255 sec, adjustable via coding addresses “c3” in the heating circuit
2 group and “c3” in the heating circuit 3 group.
29
30
Installation
Electrical Connections
(continued)
* Factory Installed high limit temperature switches.
* *
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Connection of Low Water Cut-off Device
1. Remove jumper between terminals 15(L) and 16(L).
2. Make connection for (LWCO) switching contact at terminals 15(L) and 16(L).
3. Power supply for low water cut-off device made at an available (L, N, G), terminals 12, 13 or 14.
CAUTION
The diagram shown is only a simplified conceptual drawing of a typical low water cut off (LWCO) device.
Refer to the manual specific to the device for interconnection details.
For additional information refer to the
Service Instructions.
Legend
A Low water cut-off (typical)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Electrical Connections
(continued)
* Factory Installed high limit temperature switches.
* *
Installation
Connecting External Safety Equipment
Connection at plug aBÖ .
Note: ‘Live’ contacts lead to short circuits or phase failure.
The external connection must be potential-free.
1. Remove jumper from terminals 17(L) and 18(L), 19(L) and 20(L) or 21(L) and 22(L).
2. Make connection of the safety equipment to 17(L) and
18(L), 19(L) and 20(L) or 21(L) and 22(L).
For additional information refer to the
Service Instructions.
Legend
A Minimum pressure limiter
B Maximum pressure limiter
C Further safety equipment
Note: Periphery equipment attached to the aBÖ plug must be operated on a normally closed circuit.
31
Installation
Electrical Connections
(continued)
DIN rail X0 Power supply connection
CA3B 2.5, 3.0, 3.5 and 4.0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
DIN rail X0 Power supply connection
CA3B 5.0 and 6.0
32
120 VAC/60 Hz/1 phase
(20 Amps - full load amperage)
DIN rail X0 Power supply connection (optional)
CA3B 2.5, 3.0, 3.5 and 4.0
208 Y/120VAC-60Hz - 3 phase
(20 Amps - full load amperage)
(4 wire L1, L2, L3, N, G)
WARNING
The control must be grounded.
Ensure that ‘L’, ‘N’ and ‘G’ are not interchanged.
WARNING
Incorrectly executed electrical installations can lead to injuries from electrical current and result in appliance damage.
240 VAC/60 Hz/1 phase
(20 Amps - full load amperage)
Legend
1 Factory installed terminal bridge
2 Terminal bridge must be removed on site for 240VAC
connection.
IMPORTANT
Electrical installations must comply with the latest edition of:
In the U.S.A., the National Electrical Code (NEC),
ANSI/NFPA 70 and any other state, local codes and/or regulations.
In Canada, the Canadian Electrical Code (CEC),
CSA C22.1 Part 1 and any other province, territory, local codes and/or regulations.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
EA1 Extension
Installation
Legend
DE1 Digital input 1
DE2 Digital input 2
DE3 Digital input 3
0–10V 0–10-V input fÖ Mains fÖ A Power supply for additional accessories aBJ Switching contact (floating) aVG KM-BUS
33
34
Installation
EA1 Extension
(continued)
EA1 extension
Legend
A Potential-free dry contact
B EA1 Extension
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
External block via output contact
Connection options:
EA1 extension
Contact closed:
Controlled shutdown of burner of each boiler section.
Any connected boiler circuit pump or system pump will be switched off. Shut-off devices are closed.
IMPORTANT
There is no frost protection for the heating system during the block.
Connection
CAUTION
The external connection must be potential-free.
Coding
EA1 extension
Set “5D“ (DE1), “5E“ (DE2) or “5F“ (DE3) in the
“ General ” group to 3 or 4.
External Demand via 0 –10V Input
Connection at input 0 – 10V to EA1 extension
Note: Ensure DC separation between the ground conductor and the negative pole of the on-site
voltage
0 –1V No default set supply temperature
1V Set value 50°F (10°C)
10V Set value 212°F (100°C)
Observe coding “1E” in the “General” group.
Optional setting range
0 –1V No default set supply temperature
1V Set value 86°F (30°C)
10V Set value 248°F (120°C)
Observe coding “1E” in the “General” group.
Activating the Boiler Section Valves
When the burners are shut off and all boiler section valves are closed, ventilation of the system is no longer guaranteed.
To keep the boiler section valves of the lead boiler open, perform the following tasks:
Insert an EA1 extension with fixed jumper at input DE1
Request by building management system (BMS) at input 0–10 V [e.g. 2 V 68°F (20°C)]
Required master coding: 5D: 2 and 9B: 1
Request by building management system (floating contact) at plug aVH (terminal 2–3).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
EA1 Extension
(continued)
Installation
External Operating Program - Changeover
Connection options:
EA1 extension
Connection
CAUTION
The external connection must be potential-free.
EA1 Extension
The changeover for heating circuits 1 to 3 can be implemented separately.
Legend
A Potential-free contact
B EA1 extension
Preselected operating program
(Contact open) or
9
Coding
Central heating off/DHW heating off “d5:0“ in the “Heating circuit...“ group (factory set condition)
w or
r w
Central heating off/DHW heating on
Central heating on/DHW heating on
“d5:1“ in the “Heating circuit...” group
Changed over operating program (Contact closed)
Constant operation with reduced room temperature/
DHW heating off.
Constant operation with standard room temperature, coding as per DHW heating
“64“ in the “DHW“ group.
EA1 Extension Additional Functionality
Coding
EA1 extension
Set “5D“ (DE1), “5E“ (DE2) or “5F“ (DE3) in the
“General” group to 1.
The function can be assigned to the heating circuits at coding “d8” in the “Heating circuit...” group.
Digital data inputs DE1 to DE3
Functions:
H
External heating program changeover,
separate for heating circuits 1 to 3
H
External blocking
H
External blocking with fault message input
H
External demand with minimum boiler water
temperature
H
Fault message input
H
Brief operation of the DHW recirculation pump
Input function assignment
Select the input functions by means of the following codes in the “General” group at the boiler control unit:
H
DE1: Coding address “5d”
H
DE2: Coding address “5e”
H
DE3: Coding address “5f”
DHW recirculation pump runtime for brief operation
The DHW recirculation pump can be started outside the times when it is enabled according to the time program.
The DHW recirculation pump is started by closing the contact at DE1, DE2 or DE3 by means of a pushbutton.
The runtime is adjusted via coding address “3d” in the
“General” group.
Output aBJ
Connection of a central fault messaging facility or signalling reduced mode (reduction of the heating circuit pump speed).
Select the function of output aBJ via coding address
“5c” in the “General” group.
35
36
Installation
Integrating the Control Unit into the LON
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Vitotronic 300 GW6C for CA3B 2.5, 3.0, 3.5 and 4.0
Vitotronic 300 GW6C for CA3B 5.0 and 6.0
Legend
A Boiler section 1/ lead control unit
B Boiler section 2/ lag control unit 1
C Boiler section 3/ lag control unit 2 (CA3B 5.0 and 6.0 only)
D External control unit (Vitotronic 200-H HK1B)
Note: Cascade combination of CA3B boilers cannot exceed
8 boiler sections.
Remove terminal end resistor on A to carry on LON
connection
The LON communication module is factory installed.
Vitotronic 200-H:
The LON communication module (accessory) must be plugged in.
Refer to the Vitotronic 200-H Installation and
Service Instructions.
The same participant number may not be assigned
twice within a LON.
Example for a multiple-boiler system:
Within a LON, the system numbers (Coding “98” in the
“General” group) must be the same.
Only one control unit may be encoded as fault manager.
The data transfer via LON can take up to several
minutes.
For additional information refer to the
Service Instructions.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Making the LON Connection
Installation
Establishing a LON-Connection
The Viessmann LON is designed for the BUS-topology “line” with double-sided terminating resistors (Accessories). For further information please see “Viessmann LON-Handbuch“ at www.viessmann.de/lon. The transfer distances for LON are dependent upon the electrical characteristics of the cable.
For this reason only the specified cable types may be used.
Only one type of cable may be used within a LON.
For details on Vitotronic 300 GW6C LON connections refer to page 36.
Connection with Viessmann LON cable
Installation distance
≤
23 ft. (7 m) long.
Types of cable (on-site):
2-core cable, CAT5, screened
JY(St)Y 2 x 2 x 0.8 mm (Telephone cable)
The requirements for cables and operation of the
LON interface FTT 10-A must be observed
(see www.echelon.com).
All Viessmann equipment is connected via RJ45 plugs.
Cores “1” and “2” and screening are required for the
Viessmann LON. The cores are interchangeable.
Connection with on-site cable and LON plug
Installation distance ≤ 3000 ft. (900 m) (with LON plug).
Legend
A Vitocrossal 300 CA3B control unit
B
(Vitotronic 300 GW6C)
LON connecting cable, 23 ft. (7 m) long
C Terminal end resistor
LON External LON participants
Connection with Viessmann LON cable and coupling
Installation clearance 23 to 69 ft. (7 to 21 m).
Legend
A Vitocrossal 300 CA3B control unit
B
C
D
(Vitotronic 300 GW6C)
On-site cable
Terminating resistor
LON plug
F Up to 30 participants
LON External LON participants
Connection with LON cable, on-site cable and LON junction box
Installation distance ≤ 3000 ft. (900 m)
(with LON junction box).
Legend
A Vitocrossal 300 CA3B Control unit
(Vitotronic 300 GW6C)
LON connecting cable, 23 ft. (7 m) long,
C max. 3 cables between 2 appliances
Terminal end resistor
D LON coupling
LON External LON participants
Legend
A Vitocrossal 300 CA3B control unit
B LON connecting cable, 23 ft. (7 m) long
C
D
E
F
Terminal end resistor
LON Connecting plug
On-site cable
Up to 30 participants
LON External LON participants
37
38
Installation
Installing the Boiler Panels
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
1. Install the top front cover plate with 4 screws (for CA3B
5.0 and 6.0 only).
2. Install the lower front cover plate with 6 screws from the lower front cover plate.
3. Install the top front panel (for CA3B 5.0 and 6.0 only).
4. Insert the bottom of the lower front panel in place and push into place.
5. Install the top left side and bottom left side panels.
6. Slide the top panels toward the left side.
7. Install the top right side panels.
8. Install with screws to the right side of the top panels.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Connecting Flue Gas Pipe
Installation
Legend
A Flue vent collar coupling (supplied with boiler)
IMPORTANT
Connect flue gas collector with the flue gas pipe using the shortest possible route. Avoid sharp bends.
Internal diameter boiler-flue collar
CA3B Model 2.5
3.0
in.
(mm)
10
(256)
3.5
4.5
12
(306.8)
5.0
6.0
16
(408.4)
1. Fully insert flue gas adapter inside the flue outlet
(if used with stainless steel piping).
IMPORTANT
Ensure that the venting system is fully inserted into the flue gas collector. Once installed, verify that the vent and the vent pipe coupling connections are free of leaks by using a certified leak detector.
Note: via the shortest possible run, with slight rise
(min 2-3°). Avoid sharp bends.
2. Connect flue system. Size: 10 in. (250 mm) for models 2.5 and 3.0, 12 in. (300 mm) for models 3.5 and 4.0, 16 in. (400 mm) for models 5.0 and 6.0.
Note: Support all venting components; make all connections free of load and torque stresses.
The venting system must be securely supported by an anchoring system as outlined by the venting manufacturer.
IMPORTANT
The boiler flue gas collector vent is not designed to support the weight of the venting system.
Note: The flue gas collector outlet is designed to accept most vent manufactures venting systems directly
(refer to the dimensions above). A flue gas adaptor may be required and is not included with the boiler.
If required the adaptor must be supplied by the venting manufacturer.
39
40
Installation
Connecting Neutralization System
Legend
A Neutralization system
B Hose (supplied with neutralization kit)
C Boiler siphon (supplied with boiler)
D Hose (supplied with neutralization kit)
E On site drainage system
F Boiler flue gas collector
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
IMPORTANT
The neutralization system is available as an accessory.
Refer to the Installation and Operating
Instructions for the neutralization system.
1. A behind or next to the boiler.
2. C (included with boiler) and fill with water.
3. B to the required length. Connect to syphon and neutralization system.
4. D to the condensate drain of the neutralization system and install at drainage E .
IMPORTANT
Drainage must be lower than the siphon.
WARNING
Escaping flue gas can cause severe personal injury or loss of life. Always connect the condensate drain with a syphon in order to prevent flue gas from escaping.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Condensate Connection
Installation
The Vitocrossal 300, CA3B boiler is supplied with a condensate trap (field installed). An external trap is not required when connecting the field drain to the P-trap.
Discharge tubing (field supplied) must be 1 in. diameter.
Use CPVC, PVC or other material approved by code listed below.
The drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or
F493. In Canada use CSA or ULC listed schedule 40
CPVC or PVC drain pipe, fittings and cement.
Install the condensate drain pipe with a suitable gradient.
Discharge condensate from the boiler into the drain system, either directly or (if required) via a neutralization
Legend
A Condensate drain (must be able to be inspected)
B Open or vented field supplied drainage system
Note: If the boiler is installed even with the ground, install a condensing drain above the ground max. 2 in. (50 mm).
Flue gas temp.
at partial load condensate
Boiler water return temperature
Note: The ‘amount of condensate” and the “flue gas temperature gross” graphs are independent of each
other.
IMPORTANT
Do not connect the drain pipe from any other appliance, such as a water softener backwash pipe, to the
Vitocrossal 300, CA3B condensate drain pipe.
IMPORTANT
Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable).
IMPORTANT
Always connect the drain with a P-trap or siphon to prevent flue gas from escaping into the space.
Connection (external):
7 c in. (
7
19 mm) barb fitting.
The amount of condensate to be expected during the operation of the boiler and can be read from the chart.
If the condensate outlet of the Vitocrossal 300, CA3B boiler is lower than the drain, a condensate pump must be installed. Select a pump which is approved for condensing boiler applications. To avoid condensate spillage, select a pump with an overflow switch.
The drain connection must terminate into an open or vented drain as close to the boiler as possible to prevent siphoning of the boiler drain.
41
42
Installation
Gas Connections
Legend
A Gas shut-off valve
B Low gas pressure switch
C High gas pressure switch
D Fan pressure switch
E Test fire valve
F Venturi
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Honeywell combination gas valve assembly model V4734C1010-1100-1
Honeywell combination gas valve assembly model V4734C1010-1100-1
Honeywell combination gas valve assembly model V4734C1010-1100-1
Legend
1 Burner section 1, lead
2 Burner section 2, lag 1
3 Burner section 3, lag 2
(applies for Vitocrossal 300, CA3B models 5.0 and 6.0)
Note: Each burner control requires a manual reset of low gas pressure conditions, done at the section control unit or at the burner control.
Legend
A Field supplied and installed gas shut-off valve
B Field supplied and installed union
C Field supplied and installed service gas pressure regulator (required for all installations)
D Field supplied and installed union
E Gas shut-off valve
F Built-in low gas pressure switch
G Gas pressure regulator
H High gas pressure switch
I Test firing valve
J Direct spark ignition burner with Venturi
K Fan pressure switch to low fire gas pressure regulator
1 *
7
1 a in. for individual burner sections
2 *
7
2 b in. for Vitocrossal 300, CA3B models 2.5, 3.0,
3.5 and 4.0
7
3 in. for Vitocrossal 300, CA3B models 5.0 and 6.0
Additional components may be required as specified by:
248-CMR-7:00,
N.B.C., NFPA 54 and/or ANSI Z223.1
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Gas Connections
(continued)
Installation
1. Refer to current CAN/CSA B149.1 and .2 or National
Fuel Gas Code ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing.
Pipe size to the boiler must be determined based on:
- pipe length
- number of fittings
- type of gas
- maximum input requirements of all gas appliances
in the residence.
IMPORTANT
Design piping layout in such a way that piping does not interfere with serviceable components.
2. Before connecting boiler to gas line, install ground joint union, capped drip leg and a manual equipment shutoff valve. Valves must be listed by a nationally recognized testing agency. Make boiler gas connection
3. Perform gas piping pressure test as described in the subsection.
IMPORTANT
Max. gas supply pressure: 14 “w.c.
Legend
A Manual gas shutoff valve (supplied)
B Nipple (field supplied)
C Ground joint union (recommended) (field supplied)
D Elbow (field supplied)
E Cap (field supplied)
F On site gas line
Note: Illustration shown is a generic gas piping configuration, which may vary depending on specific system layout/
requirements.
4. Identify shutoff valves as such with a tab and familiarize operator/ultimate owner of boiler with
Valve leak test
This is a test for checking the leak tightness of the valve and flange connections. It is recommended that this test be included in the scheduled inspection and maintenance procedures.
WARNING
Escaped gas may lead to an explosion, which could cause severe injuries or property damage.
IMPORTANT
This test should only be performed by a trained licensed heating contractor.
Note: Drip pocket shall be installed accordingly to
CAN/CSA B149.1 or National Fuel Code ANSI
Z223.1 / NFPA 54.
1. Open the manual gas shutoff valve A .
2. Leak test all connections with a certified leak detector.
3. Close the manual gas shutoff valve A .
4. Repair any leaks if necessary.
43
44
Installation
Gas Connections
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
The gas train on the burner meets the requirements of ASME/CSD-1.
1. Connect gas pipe A to the gas valve.
Gas connection:
Vitocrossal 300, CA3B: 2 b in. NPT for models 2.5, 3.0,
3.5 and 4.0, 3 in. NPT for models 5.0 and 6.0.
Note: Gas line weld nipples are available as an accessory
For more information refer to the Installation
Instructions for gas line weld nipples.
2. Test leak tightness of gas pipe connection using an method.
3. Purge gas line in a safe manner using an approved purge burner.
WARNING
If test pressure is too high burner and gas fittings may get damaged.
WARNING
Escaped gas may lead to explosion, which could cause severe injuries. Do not vent gas pipe above combustion chamber of boiler.
CAUTION
If gas pipe contains dirt it is recommended to install a gas filter into the gas pipe.
Vitocrossal fuel supply recommendations
- Always read and follow the instructions provided with
the gas pressure regulator.
- Install high pressure regulator a minimum of 10 ft. (3.3 m)
upsteam of the boiler fuel connection.
- Install one gas pressure regulator per boiler.
- Use a gas pressure regualtor with an outlet size equal to
the boiler fuel connection, if a change in pipe diameter is
required a concentric reducing coupling should be used.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Initial System Fill General Requirements
Installation
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 for hydronic heating systems.
IMPORTANT
Only use antifreeze specific for hydronic heating systems. Do not use automotive glycol!
Please observe that an antifreeze/water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks, radiation etc. A 40% antifreeze content will provide freeze-up protection to -31°F (-25°C).
The heating system may also contain components which may be negatively affected by antifreeze. Check entire system frequently when filled with antifreeze. Refer to the Service Instructions for further information on water quality.
The pressure relief valve must be attached to the top of the boiler or the safety supply of the boiler (see page
16). No valve, shut-off device or obstruction of any kind must be used between boiler and relief valve or on the discharge side of the pressure relief valve.
The discharge side of the pressure relief valve must continue in the same size as the outlet horizontally over the side of the boiler, and then vertically downwards to end approximately
1 ft. (300 mm) above the floor, and piped as close to a floor drain as possible. Do not install this discharge pipe to the outdoors or any area where freezing might occur or the discharge pipe could endanger life and equipment.
IMPORTANT
Secure the discharge piping from the pressure relief valve with the appropriate hangers or brackets.
CAUTION
Before the heating boiler is installed and piped into an existing system, the heating system itself must be properly flushed to remove dirt and system sludge.
Accumulations in old heating systems will tend to settle in the boiler and can lead to deposits which can cause hot spots, noise and water-side corrosion. For damages resulting from those kinds of impurities, the warranty will be null and void.
IMPORTANT
Cold water fill pressure must equal expansion tank pressure.
The boiler should be filled and properly bled of air and the cold water fill pressure should not exceed 18-20 psig.
All openings, as well as pipe connections on the boiler, should be observed for possible leaks. Once all connections are tight, the insulation can be mounted.
IMPORTANT
Ensure that there is no leak on any of the connections which are covered by the insulation.
The Vitocrossal 300, CA3B boiler is only suitable for closed hot water heating systems with pumps.
It is strongly recommended to install boiler isolation valves and above these isolation valves, drain valves in the system supply and return. With this installed, any maintenance work on the boiler or heating system, will not require draining the entire system.
When the boiler is utilized to supply heat to an indirectly heated domestic hot water tank, it is necessary that the heating loops (without a mixing valve) are equipped with flow check valves on the discharge side of the pumps to avoid reverse flow.
WARNING
Fill only suitable water in boiler. Unsuitable water quality may damage boiler.
IMPORTANT
For water quality guidelines refer to the Service Instructions.
For additional information refer to the
Service Instructions.
45
46
System Layout
General
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local
Viessmann sales representative office.
Clearances
A minimum of 2 in. (51 mm) circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained. In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0 in. (refer to local gas codes).
CAUTION
For underfloor heating applications, an additional immersion or strap-on aquastat must be installed in the low temperature underfloor loop (downstream of the mixing valve) to de-energize the pump and/or boiler to prevent overheating. High water temperatures can damage concrete slabs.
IMPORTANT
The examples on the following pages depict possible piping layouts of the Vitocrossal 300, CA3B boiler equipped with
Viessmann System Technology.
For boiler and tank combinations, please install only feasible combinations listed in the Viessmann Price List.
Please note that the following examples are simplified conceptual drawings only!
Piping and necessary componentry must be field verified.
A low water cut-off (LWCO) must be installed where required by local codes.
Proper installation and functionality in the field is the responsibility of the heating contractor.
WARNING
If a DHW storage tank other than a Viessmann Vitocell
100 or 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank.
Viessmann strongly recommends the installation of a temperature tempering valve in the DHW supply line.
IMPORTANT
DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections, shall be a minimum of 1¼ in. pipe size. This will ensure the residual head of the field supplied pump is fully utilized to overcome the resistance of the DHW heat exchanger coil and to provide sufficient water flow to the boiler heat exchanger.
In non-Viessmann DHW tank applications, perform, in addition to the above, accurate calculations for DHW tank
coil pressure drop versus boiler pump (field supplied) residual head to ensure sufficient water flow to the boiler heat exchanger. Failure to heed the above instructions may cause boiler short-cycling and inadequate DHW supply.
Note: In the following piping layout examples all pumps are field supplied.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
System Layout 1
V itocrossal 300, CA3B with...
- DHW storage tank
- one heating circuit without mixing valve
- two heating circuits with a mixing valve
System Layout
Legend
A Vitocrossal 300, CA3B boiler
B Outdoor temperature sensor !
C Low temperature heating circuit
D High temperature heating circuit
E Heating circuit pump
F Mixing valve temperature sensor ?
G Mixing valve with actuator
H Domestic hot water storage tank
I DHW tank temperature sensor %
J Expansion tank
K Boiler pump/system pump sL *
L DHW pump sA
M Low loss header
N System supply temperature sensor § / ?
* When using single speed boiler/system pumps,
a hydronic pressure bypass may be required.
O Hydronic pressure bypass (if required)
Installation of different heating circuits...
■ high-temp. circuit (radiator heating circuit)
■ low-temp. circuit (under floor heating circuit with
3-way mixing valve)
■ DHW production
The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is controlled by an accessory kit for a heating circuit with mixing valve.
IMPORTANT
System separation is required of underfloor heating systems employing non-oxygen diffusion barrier tubing.
All components on the secondary side of the heat exchanger must be made of corrosion-resistant materials.
47
System Layout
System Layout 2
Multiple (up to eight boiler sections) Vitocrossal 300, CA3B with...
- multiple heating circuits with mixing valves
- low-loss header
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
48
Legend
A Vitocrossal 300, CA3B boiler
B Low-loss header/common supply temperature
sensor § / ?
on lead boiler
C Low-loss
D DHW storage tank
E High temperature heating circuit
F Low temperature heating circuit
G Hydronic pressure bypass (if required)
H Connection to BMS (BACnet/MODbus)
I Heating
J Variable speed pump control (field supplied)
* Optional accessory (depending on system layout configuration)
Note: When using single speed boiler/system pumps, a hydronic pressure bypass may be required.
When designing a multiple Vitocrossal 300, CA3B system as shown above, please reference applicable multiple
Vitocrossal 300, CA3B technical documentation, and contact your local Viessmann Sales Representative for further assistance.
This installation example depicts a possible piping layout for multiple Vitocrossal 300, CA3B boilers equipped with
Viessmann System Technology. Please note that this example is based on a simplified conceptual drawing only!
Piping and necessary componentry must be field verified.
A low water cut-off (LWCO) must be installed where required by local codes.
Proper installation and functionality in the field is the responsibility of the heating contractor.
WARNING
If a DHW storage tank other than a Viessmann Vitocell
100 or 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank. Viessmann strongly recommends the installation of a temperature tempering valve in the
DHW supply line.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Boiler Piping in Heating/Cooling Application
Water
Chiller
Legend
A System supply
B System return
C Valve
D Supply check valve
E Circulation pump
F Automatic feed valve
G Pre-charged expansion tank
Heating /
Cooling unit
Heating /
Cooling unit
Heating /
Cooling unit
System Layout
The Vitocrossal 300, CA3B boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel to the boiler and with appropriate valves to prevent the chilled medium from entering the boiler.
The boiler piping system of a hot water heating boiler is connected to the heating coils located in the air handling units. The boiler piping system may be exposed to refrigerated air circulation and must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
Check the installation instructions of the chiller manufacturer carefully for additional requirements.
Cooling season starts: Close valve V1 and open valve V2.
Heating season starts: Close valve V2 and open valve V1.
Metal tags labelling these valves should be attached.
IMPORTANT
In the above system, the circulating pump must be operated from a separate on/off switch - not from the boiler control.
49
50
Venting
General Venting Information
Installation steps (outline)
WARNING
Ensure that the entire venting system is protected from physical damages. A damaged venting system may cause unsafe conditions.
WARNING
The venting system is approved for indoor installations only. Do not install the venting system outdoors.
IMPORTANT
Boiler operation in marine environments (damp, salty coastal areas):
The service life of the Vitocrossal 300, CA3B boiler’s exposed metallic surfaces, such as the casing and fan housing, is directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray, coupled with relative humidity, can lead to degradation of the exposed metallic surfaces mentioned above.
Therefore, it is imperative that boilers installed in such environments not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air dependent vent systems; i.e. using room air for combustion. The indoor air will have a much lower relative humidity and hence, the corrosion will be minimized.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Route vent pipe as directly as possible and with as few bends as possible to the boiler.
Check proper location of gaskets in rigid PP(s) pipe collars.
(Only use supplied parts with the polypropylene venting
system.) Apply water to lubricate the joint ends of the
vent pipe collar and if used, the air intake pipe collar.
Slide pipes into each other with a gentle twisting motion.
Condensate must drain from the flue pipe to the boiler.
Ensure a suitable gradient of at least 2º-3º based on the vent manufacturer’s system design [example: for a 3º system approx. 2 in. per 3.3 ft. (50 mm per 1 m) on any horizontal venting components].
Use a hacksaw or sheet metal snips (for stainless steel)
to cut pipes to length (if necessary). Use a file to
smooth rough edges. Pipe must be round and not bent
into an oval shape.
IMPORTANT
When cutting pipes to length, deburr and clean pipes.
For stainless steel and PP(s) venting systems:
In conjunction with these instructions, follow the installation instructions supplied by the special venting manufacturer.
If using room air-independent venting system, connect the air intake pipe (from outdoors) to the combustion air intake kit. If room air-dependent venting system is used, the air is drawn into the burner inlet through the screens on the right side of the boiler.
Recommended venting practice
When installing a venting system the following recommended venting practices apply:
Keep length and number of 90º elbows to a minimum.
Try not to use back-to-back 90º elbows.
Use 45º elbows where possible to minimize the number of 90º elbows in case redirection of flue gas is required.
The special vent system shall not be routed into, through, or within any other vent such as an existing masonry or factory-built chimney.
Exception:
A masonry chimney flue may be used to route the venting system only if no other appliance is vented in the same flue.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
General Venting Information
(continued)
Approved venting materials
Part
Exhaust pipe and fittings
Material
Stainless steel
PP(s)
Polypropelene
Combustion air intake pipe and fitting
Stainless steel
Galvanized steel
PVC-DWV
Schedule 40
CPVC
Schedule 40
ABS-DWV
Schedule 40
PP(s)
Polypropelene
Pipe cement, primer
(for combustion air intake pipe)
PVC
CPVC
ABS
Venting
Certified to Standards
UL1738
“Venting systems for gas-burning appliances, Categories II,
III, IV”
ULC S636
“Standard for Type BH gas venting systems”
Applicability
U.S.A./Canada
UL1738
“Venting systems for gas-burning appliances, Categories II, III, IV”
ULC S636
“Standard for Type BH gas venting systems” Class IIC 110ºC
No applicable standards
Suitable for outdoor use
ANSI/ASTM D2661
CSA B181.1
ULC S102.2
ANSI/ASTM D2665, D1785
CSA B137.3, B181.2
ANSI/ASTM F441
ANSI/ASTM D2661
CSA B181.1
ULC S102.2
ANSI/ASTM D2665, D1785
CSA B137.3, B181.2
ANSI/ASTM F441
ANSI/ASTM D2661
CSA B181.1
ULC S102.2
ANSI/ASTM D2665, D1785
CSA B137.3, B181.2
ANSI/ASTM F441
UL1738
“Venting systems for gas-burning appliances, Categories II, III, IV”
ULC S636
“Standard for Type BH gas venting systems” Class IIC 110ºC
ANSI/ASTM D2564
CSA B137.3
ANSI/ASTM F493
CSA B137.6
ANSI/ASTM D2235
CSA B181.1/B182.1
CAUTION
On the job site, ensure that non-listed combustion air pipe materials are not inadvertently used instead of listed vent pipe material.
CAUTION
Do not use cellular (foam) core pipe material to vent this
Vitocrossal boiler.
51
Venting
General Venting Information
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Vent termination location requirements (for installations in Canada)
The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2. The flexible vent pipe can only be used in vertical installations.
A vent must NOT terminate...
1 .....directly above a paved sidewalk or paved driveway which is located between two single-family dwellings and serves both dwellings.
8 .....underneath a veranda, porch or deck, unless:
the veranda, porch, or deck is fully open on a minimum
of two sides beneath the floor, and
the distance between the top of the vent termination and
the underside of the veranda, porch, or deck is greater
than 1 ft. (0.3 m).
2 .....less than 7 ft. (2.13 m) above a paved sidewalk or a paved driveway located on public property.
9 .....in areas where condensation may cause problems, such as above planters, patios, or adjacent to windows where flue gases may cause fogging.
3 .....within 6 ft. (1.83 m) of a mechanical air supply inlet * 1 to any building (dryer vents, non-sealed combustion furnace and hot water heater vents are considered to be mechanical air inlets).
10 ....within 3 ft. (0.9 m) to the property line (advisable, not mandatory; please check with local building authorities and municipal bylaws).
11 ....at a location where ice formation on the ground can present a hazard.
4 .....above a meter/regulator assembly within 3 ft. (0.9 m) horizontally of the vertical center line of the regulator vent outlet and to a maximum vertical distance of 15 ft. (4.5 m).
5 .....within 3 ft. (0.9 m) of any gas service regulator vent outlet.
12 ....so that the flue gases are directed toward brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the flue gases.
6 .....less than 1 ft. (0.3 m) above grade level or anticipated snow level (consult local building authorities or local weather office). Locate the vent termination in such a way that it cannot be blocked by snow.
7 .....within the following distances of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance:
1 ft. (0.3 m) for inputs up to and including 100 000
Btu/h / 30 kW.
3 ft. (0.9 m) for input exceeding 100 000 Btu/h / 30 kW.
13 ....where discharging hot flue gases may cause property damage or personal injury.
14 ....within 3 ft. (0.9 m) from an inside corner of outside walls.
* 1 Including heat recovery units.
52
Vent Termination Location Requirements (for installations in the U.S.A.)
The vent must be installed observing local regulations in addition to National Codes, ANSI-Z223.1 or NFPA 54.
The flexible vent pipe can only be used in vertical installations.
A vent must NOT terminate...
6 .....in areas where condensation may cause problems, such as above planters, patios, or adjacent to windows where flue gases may cause fogging.
1 .....less than 7 ft. (2.13 m) above a paved sidewalk or a paved driveway located on public property.
7 .....within 3 ft. (0.9 m) to the property line (advisable, not mandatory; please check with local building authorities and municipal bylaws).
2 ....within 4 ft. (1.2.m) horizontally from service regulator vents, electric and gas meters as well as relief equipment.
3 ....at least 3 ft. (0.9 m) above any forced air inlet located within 10 ft. (3 m).
8 .....at a location where ice formation on the ground can present a hazard.
9 .....so that the flue gases are directed toward brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the flue gases.
4 .....less than 1 ft. (0.3 m) above grade level or anticipated snow level (consult local building authorities or local weather office). Locate the vent termination in such a way that it cannot be blocked by snow.
5 .....within 1 ft. (0.3 m) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion inlet of any other appliance.
10 ....where discharging hot flue gases may cause property damage or personal injury.
11 ....within 3 ft. (0.9 m) from an inside corner of outside walls.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
General Venting Information
(continued)
Venting
Flashing and storm collar installation
Flashings and storm collars are field supplied. Flashings and storm collars suitable for Type B vent materials (or better) may be used.
To obtain flashings and storm collars, please contact your local vent material supplier. Follow the installation instructions supplied by the special venting manufacturer.
Follow local codes to properly isolate the exhaust vent pipe when passing through floors, ceiling and roof.
Always check the marking on the pipe to make sure you are using the correct material.
Connecting Combustion Air Intake for Direct Vent
Room air independent operation (direct vent)
The connection set for the combustion air intake kit is available as an accessory.
Refer to the installation instructions “combustion air intake kit”.
Additional Requirements for Stainless Steel Vent Pipe Material
M&G / Duravent www.duravent.com
Selkirk Canada Corporation www.selkirkchimney.com
Security Chimneys
International Ltd.
www.securitychimneys.com
Jeremias Inc.
www.jeremiasinc.com
METAL-FAB, INC.
www.mtlfab.com
ICC - Industrial Chimney Co.
www.icc-rsf.com
Novaflex www.
flexmaster.com
Enervex Inc.
(formerly Exhausto) www.enervex.com
Van-Packer Co. Inc.
www.vpstack.com
Note: For SS venting system order transition adaptors from the above mentioned suppliers.
IMPORTANT
For exhaust vent pipe material:
Do not use any other vent material.
WARNING
The use of vent material other than listed UL/ULC stainless steel and PPs positive pressure vent pipe and fittings can cause property damage, severe personal injury and/or loss of life.
Use stainless steel venting system (UL/ULC listed for category IV) for horizontal or vertical venting of the
Vitocrossal boilers.
Contact one of the suppliers (see listing on left) to order.
Prior to installation, check that the correct single-wall vent parts were ordered and supplied.
For sealed combustion systems that are vertically vented, a Viessmann vacuum relief damper may be needed to protect the vent system against vacuum conditions.
This very rare occurrence can happen when a boiler is firing at maximum capacity and the burner cycle is suddenly interrupted.(ie. power failure) For more information on this device, or questions specific to your application, please consult with the vacuum relief damper installation instructions or contact your local Viessmann representative.
Exhaust vent/air intake connection to boiler
The vent connection to the Vitocrossal boiler may require a starter stainless steel adaptor (supplied by others).
Combustion air intake
If using room air-independent venting system, the combustion air intake kit must be used. Connect the air intake pipe (from outdoors) to the adaptor provided.
If room air-dependent venting system is used, the air is drawn into the burner inlet through the combustion air inlet screens located on the side of the boiler.
53
54
Venting
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material
Requirements for PP(s) and stainless steel
The venting system must be installed by a licensed professional heating contractor familiar with the operation and maintenance of heating appliances and venting.
Before installing, ensure that the complete installation literature has been read. Failure to follow proper installation procedures as stated in these instructions, including vent pitch and proper appliance connections, may violate local, provincial/state, or national codes and cause unsafe conditions which may lead to severe property damage or personal injury.
The venting system must be installed in accordance with local building code requirements as well as national codes.
For installations in Canada use CAN/CSA-B149.1 Natural
Gas Installation Code or CAN/CSA-B149.2 Propane
Installation Code as applicable; in the U.S. use the National
Fuel Gas Code ANSI Z223.1 or NFPA Standard 54.
To ensure safe operation of the appliance, Viessmann recommends that the system be inspected once a year by a qualified service technician.
Every venting system must be planned and installed for optimum performance and safety. These Installation
Instructions are designed to help you determine venting requirements and limitations with respect to installation.
Please read and follow these instructions carefully.
It is the responsibility of the installer to contact local building and fire officials concerning any installation restrictions and/or inspection requirements that may apply. Permits may be required before commencement of the installation.
The vent termination for side wall vent installations should be located on a wall that is least affected by prevailing winds. High winds may affect boiler operation and/or degrade the exterior finish of the wall. They may also cause recirculation of the appliance’s own flue products. Recirculation of flue products can result in poor combustion and inlet condensation problems.
If wind is a problem, steps must be taken to shield the vent termination from high winds, such as building a fence or planting shrubs. Ensure that the total equivalent vent length is not exceeded.
Because of its sealed combustion chamber, the Vitocrossal
300, CA3B gas-fired condensing boiler is suitable for operation with direct vent room air independent operation
(when using air intake system).
Use only material listed in the table on page 51, entitled
“Approved venting materials”.
The remaining space surrounding a chimney liner, gas vent, or special gas vent or plastic piping installed within a masonry, metal or factory-built flue shall not be used to supply combustion air to the boiler. A separate combustion air intake pipe routed back to the boiler can be used in the remaining space if required, the boiler venting system is approved for zero clearance, and can be run directly beside the combustion air intake pipe.
IMPORTANT
Potential gaps between the vent/air intake pipes and the surrounding construction which may cause air, rain or flue gases to leak into the wall or the building, must be sealed with approved sealant /caulking to prevent leakage of any kind.
This PP(s) vent system is constructed from flame-retardant plastic [polypropylene rated for a maximum temperature of 230ºF (110ºC)].
The PP(s) venting system components must be listed to ULC S636 / UL-1738 (contact one of the venting suppliers below).
DO NOT mix pipe, fittings, or joining methods from different vent system manufacturers.
Refer to the vent length requirements on page 59 for two pipe vent installations and page 64 for single pipe installations. These requirements must be observed.
If using flexible vent or air intake pipe, reduce the max. equivalent length allowed by 25%.
The PP(s) venting material can be extended (without exceeding the maximum equivalent length) beyond the outside wall of the structure, provided that the PP(s) venting material is installed in an enclosed, insulated and waterproof chase that is acceptable for outdoor installation. The vent termination location must comply with the instructions and codes stated in this manual.
IMPORTANT
Side wall vent installations must include a protective screen.
Vent System Suppliers
Use special venting system (UL/ULC listed for Category
IV) for exhaust vent material of the Vitocrossal boilers.
Contact one of the following suppliers to order parts.
Both suppliers deliver PP(s) rigid and flexible vents in a variety of sizes.
M&G / Duravent www.duravent.com
Centrotherm InnoFlue www.centrotherm.us.com
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Vent Requirements
Venting
Combustion air supply, room air dependent application only
The Vitocrossal 300, CA3B boiler requires fresh air for safe operation and must be installed in a mechanical room where there are provisions for adequate combustion and ventilation air.
Provisions for combustion and ventilation air must be made in accordance with CAN/CSA-B149.1 or .2 Natural
Gas Installation Codes (latest edition) (for installations in
Canada) or in accordance with sections for Combustion and Ventilation Air, of the National Fuel Gas Code, ANSI
Z223.1 (latest edition) or applicable provisions of local codes (for installations in the U.S.A.)
Follow local codes to properly isolate the vent pipe when passing through floors, ceilings and roof.
Whenever possible, install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area.
Refer to national codes for duct sizing. Round ducts may be used.
The boiler must be vented and supplied with combustion air and exhaust vents as described in this section. Ensure the vent and combustion air supply comply with these instructions.
WARNING
Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, which can cause severe personal injury or loss of life.
The Vitocrossal 300, CA3B boiler location should never be under negative pressure. Exhaust fans, attic fans, or dryer fans may cause air to be exhausted at a rate higher than the air can enter the structure for safe combustion.
Corrective action must be taken to ensure enough air is available. Never cover the boiler or store debris or other materials near the boiler, or in any way block the flow of adequate fresh combustion air to the boiler.
You must know the free area of louvers used to cover up the combustion and ventilation openings in closet installations. If you do not know the free area, assume
20% for wood louvers and 60-75% free area for metal louvers. When using louvers, the openings have to be made larger.
For example, a free 14 in. x 6 in. (356 mm x 152 mm) opening becomes a 14 in. x 10 in. (356 mm x 254 mm) opening for a grill containing metal louvers.
CAUTION
Do not store chemicals containing chlorine or other corrosive materials near the boiler, such as bleach, cleaning solvents, detergents, acids, hair spray, spray cans, paint thinners, paint, water softener salt, perchloroethylene, or carbon tetra chloride.
55
Venting
Direct Venting (Two Pipe System)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Stainless steel or plastic mesh
Min. 36 in.
(915 mm)
Intake terminal 90 o
Exhaust vent terminal 45 o
Grade or max. snow level
Min. 2 in. (50 mm)
Max. 36 in. (915 mm)
Vent
Min. 12 in.
(305 mm)
Air
Min. 2 in. (50 mm)
Side wall vent termination [stainless steel, CPVC or PP(s)]
IMPORTANT
The exhaust vent/air intake system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the “Natural Gas and Propane
Installation Code” CAN/CSA-B149.1 (Canada), or the
“National Fuel Gas Code” ANSI Z223.1 (NFPA 54) (U.S.A.).
IMPORTANT
For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).
WARNING
Vent termination must be at least 12 in. (305 mm) above the anticipated snow level (consult your local building authorities or local weather office). Locate vent termination in such a way that it cannot be blocked by snow.
Combustion Air Intake Filter (field supplied)
56
Support bracket
Side wall
Caulk
* Field fabricated vent riser
Vent
*
Termination elbow with screen
Max. 36 in.
(915 mm)
Min. 12 in.
(305 mm)
Grade or max. snow level
A combustion air inlet filter may be installed at any point in the combustion air inlet ducting (field supplied).
Sized for 16” X 25” X 1” high performance furnace filter acceptable filters include 3M 1000, 1500, or 1900 series filters or equivalent. Ensure location of installation allows for adequate services clearance for filter inspection and maintenance.
Refer to filter manufactures instructions for cleaning replacement intervals, filter care, etc.
Do not decrease the combustion air intake diameter, the diameter must be maintained through the combustion air intake ducting.
Using combustion air filters remove dust particles from supplied combustion air. It is the responsibility of installing contractor/designer or engineer to make sure any impurities contain in combustion air supply to the boiler, that can affect the operation or life expectancy of the components, are removed and dealt with.
Note: The boiler combustion air inlet connection is not designed to support the weight of the combustion air ducting, filter or filter housing ensure that the combustion air ducting is properly supported.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Side Wall Venting
Venting
Side wall vent termination [stainless steel or PP(s)]
IMPORTANT
For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).
Min. 12 in.
(305 mm)
Exhaust vent terminal 90 o
Min. 2 in.
(50 mm)
Max. 36 in.
(915 mm)
Grade or max. snow level
Support bracket
Termination elbow with screen
Side wall
Caulk
Vent
*
Max. 36 in.
(915 mm)
Min. 12 in.
(305 mm)
Grade or max. snow level
* Field fabricated vent riser
Flue
Component Installation Guide
Flashing and storm collar installation
Flashings and storm collars are field supplied.
Flashings and storm collars suitable for Type B vent materials (or better) may be used.
To obtain flashings and storm collars, please contact your local vent material supplier. Follow the installation instructions supplied by the special venting manufacturer.
Elbow - Equivalent Length
Equivalent Length
Elbow size
7
4 in. (100 mm)
45º
90º
1 ft. (0.3 m)
1.6 ft. (0.5 m)
6 in. (150 mm), 8 in. (200 mm), 10 in. (250 mm),
12 in. (300 mm), 14 in. (350 mm), 16 in. (400 mm)
5 ft. (1.5 m)
10 ft. (3 m)
57
Venting
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Vent Termination Location Requirements - Vertical b a
For sloped roof applications with distance b greater than 18 in. (450 mm)
a b
For sloped roof applications with distance b less than 18 in. (450 mm) a
The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2
(for installations in Canada) or ANSI-Z223.1 or NFPA 54
(for installations in the U.S.A.).
WARNING
Vent termination must be at least 12 in. (305 mm) above the anticipated snow level (consult your local building authorities or local weather office). Locate vent termination in such a way that it cannot be blocked by snow.
A vent used in a special venting system with positive vent pressure and passing through a roof shall extend at least 18 in. (450 mm) above the highest point where it passes through the roof and any other obstruction within a horizontal distance of 18 in. (450 mm).
The special vent system shall not be routed into, through, or within any other vent such as an existing masonry or factory-built chimney.
IMPORTANT
A masonry chimney flue may be used to route the venting system only if no other appliance is vented in the same flue.
Legend a minimum 18 in. (450 mm) b <18 in. (450 mm)
58
For flat roof applications
Installation of Support System - PP(s)
Bracing
Contact your local vent material supplier for more information specific to your installation. Braces are required to stabilize an installation. There are different types and their use and spacing vary.
The following types of braces are available at your local vent material supplier:
wall band
wall band extension
guy wire band
roof brace.
IMPORTANT
Ensure that the venting system is properly supported; the boiler is not designed to support the weight of the venting system.
Vent system suppliers
To order approved PP(s) vent system contact the following suppliers.
M&G / Duravent www.duravent.com
Centrotherm InnoFlue www.centrotherm.us.com
IMPORTANT
For exhaust vent pipe material:
Use only ULC S-636 / UL 1738 vent material.
The venting system must be securely supported by a support system suitable for the weight and design of the materials employed. Contact your vent material supplier for more information specific to your installation.
Supports are used to transfer the weight of an installation to the building structure. There are different types of supports and their capacity varies with each type and diameter.
The following support types are available at your local vent material supplier:
anchor plate
wall support
roof support
floor support
suspension band (hanger).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Venting Options - Stainless Steel/PP(s)
Two Pipe System - Vertical Exhaust/Vertical Air Intake
Flue
Air a - Equivalent exhaust length b - Equivalent air intake length
(see chart for max. air intake length)
Vertical intake and exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter in. (mm)
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
ft. (m) ft. (m)
10 (250)
10 (250)
66 (20)
99 (30)
2.5
10 (254)
12 (300)
12 (300)
99 (30)
198 (60)
3.0
10 (250)
10 (254)
12 (300)
10 (250)
33 (10)
52 (16)
12 (300)
99 (30)
198 (60)
Vertical intake and exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
in. (mm)
ft. (m) ft. (m)
3.5
12 (306.8)
12 (300)
12 (300)
66 (20)
198 (60)
12 (300)
14 (350)
131 (40)
198 (60)
4.0
12 (300)
12 (300)
50 (15)
115 (35)
12 (306.8)
12 (300)
14 (350)
66 (20)
198 (60)
Vertical intake and exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter in. (mm)
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
ft. (m) ft. (m)
5.0
16 (408.4)
16 (400)
198 (60)
198 (60)
6.0
16 (408.4)
16 (400)
164 (50)
198 (60)
* A minimum of 20 ft. (6 m) of equivalent exhaust vent length must be included in the equivalent vent length (a+b) calculation.
If flexible vent or flexible air-intake pipe are used, the total max. equivalent length will be reduced by 25%.
59
Venting Options - Stainless Steel/PP(s)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Two Pipe System - Vertical Exhaust/Vertical Air Intake
(continued)
IMPORTANT
All PP(s) vent termination elbows, must be secured in place as specified by manufacturer.
IMPORTANT
For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).
Legend
A Support system
B Flashings
C Exhaust with screen
D Combustion air intake with screen
Dimensions
a min. 18 in. / max. 48 in.
b min. 0 in.
c min. 12 in.
d 6 in. over max. local snow level (check with your local weather office for details).
Vertical Vent Installation Sloped Roof
60
Vertical Vent Installation Flat Roof
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Venting Options - Stainless Steel/PP(s)
Two Pipe System - Horizontal Exhaust/Horizontal Air Intake
Flue
Min. 36 in.
(915 mm)
Air a - Equivalent exhaust length b - Equivalent air intake length
(see chart for max. air intake length)
Horizontal intake and exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
in. (mm)
ft. (m) ft. (m)
10 (250)
10 (250)
49 (15)
66 (20)
2.5
10 (254)
12 (300)
12 (300)
99 (30)
198 (60)
3.0
10 (250)
10 (254)
12 (300)
10 (250)
16 (5)
26 (8)
12 (300)
33 (10)
180 (55)
Horizontal intake and exhaust
Vitocrossal 300 CA3B Boiler model 3.5
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter
Exhaust vent diameter
Max. combustion air intake length (b)
in. (mm)
12 (306.8)
12 (300)
in. (mm) 12 (300)
ft. (m) 50 (15)
12 (300)
14 (350)
66 (20)
Max. total equivalent length (a+b)* ft. (m) 99 (30) 198 (60)
12 (300)
12 (300)
50 (15)
66 (20)
4.0
12 (306.8)
12 (300)
14 (350)
50 (15)
149 (45)
14 (350)
14 (350)
131 (40)
198 (60)
Horizontal intake and exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter in. (mm)
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
ft. (m) ft. (m)
5.0
16 (408.4)
16 (400)
131 (40)
198 (60)
6.0
16 (408.4)
16 (400)
50 (15)
180 (55)
* A minimum of 20 ft. (6 m) of equivalent exhaust vent length must be included in the equivalent vent length (a+b) calculation.
Note:
61
Venting Options - Stainless Steel/PP(s)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Two Pipe System - Vertical Exhaust/Horizontal Air Intake
Flue
Air a - Equivalent exhaust length b - Equivalent air intake length
(see chart for max. air intake length)
Horizontal intake and vertical exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter in. (mm)
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
ft. (m) ft. (m)
10 (250)
10 (250)
66 (20)
99 (30)
2.5
10 (254)
12 (300)
12 (300)
99 (30)
198 (60)
3.0
10 (250)
10 (254)
12 (300)
10 (250)
33 (10)
52 (15)
12 (300)
99 (30)
198 (60)
62
Horizontal intake and vertical exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
in. (mm)
ft. (m) ft. (m)
3.5
12 (306.8)
12 (300)
12 (300)
66 (20)
198 (60)
12 (300)
14 (350)
131 (40)
198 (60)
4.0
12 (300)
12 (300)
50 (15)
115 (35)
12 (306.8)
14 (350)
14 (350)
66 (20)
198 (60)
Horizontal intake and vertical exhaust
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Combustion air intake diameter in. (mm)
Exhaust vent diameter
Max. combustion air intake length (b)
Max. total equivalent length (a+b)*
in. (mm)
ft. (m) ft. (m)
5.0
16 (408.4)
16 (400)
198 (60)
198 (60)
6.0
16 (408.4)
16 (400)
164 (50)
198 (60)
* A minimum of 20 ft. (6 m) of equivalent exhaust vent length must be included in the equivalent vent length (a+b) calculation.
If flexible vent or flexible air-intake pipe are used, the total max. equivalent length will be reduced by 25%.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Individual Burner Intake Ducting
Venting Options - Stainless Steel/PP(s)
The combustion air intake ducting equivalent length must be calculated based on the single combustion air intake pipe with the longest equivalent length (as shown in the illustration with grey fill).
Refer to pages 59 through 62 to determine maximum equivalent lengths.
For roof and vent spacing refer to page 60.
For combustion air intake duct connection to the boiler, refer to the “Combustion Air Intake Kit”
Installation Instructions.
IMPORTANT
Ensure that the combustion air intake ducting is fully supported as the burner is not designed to carry the weight of the ducting.
63
Venting Options - Stainless Steel/PP(s)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Single Pipe System - Vertical Exhaust/Room Air Dependant
Flue
64
Room
Combustion
Air Opening
Air Air a - Equivalent exhaust length
Vertical exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter in. (mm)
Max. vent equivalent length ft. (m)
Vertical exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter in. (mm)
Max. vent equivalent length ft. (m)
Vertical exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter in. (mm)
Max. vent equivalent length ft. (m)
2.5
10 (254)
10 (250)
198 (60)
3.5
12 (300)
12 (306.8)
14 (350)
198 (60) 198 (60)
5.0
16 (408.4)
16 (400)
198 (60)
10 (250)
108 (33)
3.0
10 (254)
12 (300)
198 (60)
4.0
12 (300)
12 (306.8)
14 (350)
198 (60) 198 (60)
6.0
16 (408.4)
16 (400)
198 (60)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Venting Options - Stainless Steel/PP(s)
Single Pipe System - Horizontal Exhaust/Room Air Dependant
Room
Combustion
Air Opening
Air Air
Flue a - Equivalent exhaust length
Horizontal exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter
Max. vent equivalent length
in. (mm) ft. (m)
Horizontal exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter
Max. vent equivalent length
in. (mm) ft. (m)
Horizontal exhaust/room air dependant
Vitocrossal 300 CA3B Boiler model
Boiler flue collar (internal diameter) in. (mm)
Exhaust vent diameter in. (mm)
Max. vent equivalent length ft. (m)
10 (250)
125 (38)
2.5
10 (254)
12 (300)
198 (60)
12 (300)
164 (50)
3.5
12 (306.8)
14 (350)
198 (60)
5.0
16 (408.4)
16 (400)
198 (60)
10 (250)
82 (25)
3.0
10 (254)
12 (300)
198 (60)
12 (300)
115 (35)
4.0
12 (306.8)
14 (350)
198 (60)
6.0
16 (408.4)
16 (400)
198 (60)
65
66
Venting Options - Stainless Steel/PP(s)
Multiple Boiler Installations
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
Horizontal vent termination
36 in. min.
(915 mm min.)
Note: 36 in. (915 mm) minimum distance apart for horizontal vent terminations.
Vertical vent termination
6 in. min. (150 mm min.)
4 in. min.
(100 mm min.)
Note: 4 in. (100 mm) minimum distance apart for vertical vent terminations.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Installation
67
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