VIESSMANN ZK05300 Burner Combustion Air Intake Adaptor Kit Instruction Manual

VIESSMANN ZK05300 Burner Combustion Air Intake Adaptor Kit

Safety and Installation Requirements

Please ensure that these instructions are read and understood before starting any service work. Failure to comply with these instructions may cause product/property damage, severe personal injury and/or loss of life.

Working on the equipment
The installation, adjustment, service and maintenance of this product 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, burner or control.
Ensure that main power to the equipment being serviced is off. Ensure that the main fuel supply valve to the boiler is closed.
Take precautions to avoid accidental activation of power or fuel during service work.
Do not perform service work on any component part without ensuring safe operation of the heating system. When replacing parts, use original Viessmann or Viessmann approved replacement parts.
Refer to the Installation Instructions applicable to this boiler.

Description

The boiler air intake adaptors are an exclusive Viessmann design to deliver combustion air directly to the cylinder burner.
The adaptor kit consists of:

• Burner intake adaptor
• Retaining clamps
• Hardware
• Burner intake adaptor extensions
• Combustion air opening bezels

Whenever possible install the boiler near an outside wall to duct fresh air directly to the boiler.

Removing the Boiler Combustion Air Intake Panels

1. Using the allen key, remove the mounting screws from the top of the panel.
   Note: If this boiler has direct combustion air intake piping installed, disconnect the piping prior to removing the combustion air intake panels.

2. Lift the panel and pull forward to remove from the boiler.

Installing the Combustion Air Intake Adaptor

1. Using the hardware provided, bolt the burner intake adaptor to the burner air intake flange.
2. Install the burner intake adaptor extensions to the burner intake adaptor and secure with the clamp provided.

Installing the Intake Panels CA3

1. Remove 4 screws and remove the filter bracket and filter.
2. Remove 4 screws and remove the combustion air intake grill.
3. Install the combustion air opening bezels into the boiler combustion air intake panels.
4. Reinstall the panels to the boiler.

Installing the Intake Panels CA3B

1. Install the lift off panels.
2. Using the allen key, tighten the mounting screws to the top of the panel.

Dimensions (for adaptor kit 7571003 / 7735723)

dual fuel

| CA3 3.5

dual fuel

| CA3 4.0

dual fuel

a| in.| 32| 34| 34| 35
| (mm)| (812)| (865)| (865)| (910)
b| in.| 28e| 34| 34| 32a
| (mm)| (720)| (865)| (865)| (820)
c| in.| 68| 74| 74| 74
| (mm)| (1750)| (1880)| (1880)| (1880)
Boiler| CA3B| CA3B| CA3B 3.5| CA3B 4.0
---|---|---|---|---
model| 2.5 & 3.0| 2.5 & 3.0

dual fuel

| CA3B 3.5

dual fuel

| CA3B 4.0

dual fuel

a| in.| 30| 32| 32| 34
| (mm)| (762)| (812)| (812)| (860)
b| in.| 28b| 32a| 34| 32a
| (mm)| (720)| (820)| (865)| (820)
c| in.| 68c| 74| 74| 74
| (mm)| (1750)| (1880)| (1880)| (1880)

Dimensions (for adaptor kit 7571004 / 7735724)

Boiler models| CA3 5.0 & 6.0

CA3 5.0 & 6.0 dual fuel

---|---
a| in.| (mm)| 34 (865)
b| in.| (mm)| 32a (820)
c| in.| (mm)| 34 (865)
d| in.| (mm)| 74 (1880)
Boiler models| CA3B 5.0

CA3B 5.0 dual fuel

| CA3B 6.0

CA3B 6.0 dual fuel

---|---|---
a| in.| (mm)| 32 (812)| 34 (860)
b| in.| (mm)| 32a (820)| 32a (820)
c| in.| (mm)| 34 (860)| 32a (820)
d| in.| (mm)| 74 (1880)| 74 (1880)

Note: dimensional tolerance of ! a in. (! 5 mm)

Combustion Air Intake Duct

• Equivalent length is based on the longest  run of the combustion air intake even when using a common header.
  Refer to the Vitocrossal 300 Installation Instructions for max. equivalent lengths.

Install field supplied combustion air intake ducting to the burner intake adaptor extensions using supplied gear clamp.

IMPORTANT
The burner inlet adaptors are not designed to support the weight of the venting system. Support all venting components; make all connections free of load and torque stresses. The venting system must be securely supported by an anchoring system.
If connecting the individual burner combustion air intakes of a single boiler to a common combustion air intake, it must have a cross section area equivalent to;

Boiler models| Common combustion air intake diameter
---|---
CA3 / CA3B 2.5 & 3.0| 10 in. (250 mm)
CA3 / CA3B 3.5 & 4.0 CA3 / CA3B 2.5 to 4.0 DF| 12 in. (300 mm)
CA3 / CA3B 5.0 & 6.0 CA3 / CA3B 5.0 to 6.0 DF| 16 in. (400 mm)

Individual Burner Combustion Air Intake Ducts

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 the Vitocrossal 300 Installation Instructions for max. equivalent lengths.
Install field supplied combustion air intake ducting to the burner intake adaptor extensions using supplied gear clamp.

IMPORTANT
The burner inlet adaptors are not designed to support the weight of the venting system. Support all venting components; make all connections free of load and torque stresses. The venting system must be securely supported by an anchoring system.

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