Viess VITOCROSSAL 200 CM2 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2
Gas condensing boiler with MatriX radiant burner
VITOCROSSAL 200
5592 702 GB 2/2011 Dispose after installation.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas appliances must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
■ Gas Safety (Installation & Use) Reg-
ulations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a mains isolator.
■ Safeguard the system against unau-
thorised reconnection.
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
Safety instructions
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Preparing for installation................................................................................... 4
Installation sequence
Siting and levelling the boiler................................................................................ 5
Fitting the thermal insulation................................................................................ 6
■Thermal insulation mats.................................................................................... 6
■Side panels....................................................................................................... 7
■Front panels...................................................................................................... 8
■Thermal insulation mat at the back and back panels........................................ 9
Control unit installation......................................................................................... 9
Connecting on the heating water side.................................................................. 10
Making the safety connections ............................................................................ 12
Electrical connections and top panel installation.................................................. 12
■ Cables............................................................................................................... 12
■ Connections to the control unit base................................................................. 13
■ Top panels and covers...................................................................................... 14
Connections on the flue gas side......................................................................... 14
■ Flue outlet and siphon....................................................................................... 14
■ Condensate drain pipe...................................................................................... 16
Burner installation................................................................................................. 17
Connecting the burner on the gas supply side..................................................... 18
Connecting the burner electrically........................................................................ 19
Fitting the burner hood......................................................................................... 20
Commissioning and adjustment........................................................................... 21
Index
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Clearance dimensions
C
A
A
B
b
500 (250)
600
a
500 (50)
ABoiler
BBurner
CAdjustable anti-vibration boiler sup-
ports (accessories)
Dimensions in brackets are minimum
clearances.
Dim. a: 500 mm
Dim. b: 400 mm
When using Viessmann accessories for
two-boiler systems, dimensions a and b
apply.
Installation instructions flue gas
header and hydraulic system
connection
Preparing for installation
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!Please note
Damage to the flue outlet can
lead to flue gas escaping.
Never lift or move the boiler by
the flue outlet.
Note
A suitable condensate drain (maximum
50 mm above floor level) must be avail-
able in the installation room if the boiler
is installed at ground level.
A
2.
1.
1. Insert adjusting screws A from
above into the base rails.
Note
The adjusting screws are supplied in
the pack.
2. Level the boiler horizontally. Special
foundations are not required.
Note
We recommend the installation of the
boiler on adjustable anti-vibration
supports (accessories).
Insert these from below into the base
rails.
Siting and levelling the boiler
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Note
All required components are included in
the carton containing the thermal insula-
tion.
Thermal insulation mats
1.
2.
3.
3.
Note
In the case of balanced flue operation,
attach the ventilation air pipe before fit-
ting the thermal insulation panels.
Installation instructions for acces-
sories for balanced flue opera-
tion
Fitting the thermal insulation
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Side panels
8x
6 x 10
4x
6 x 10
3.
3.
4. 4.
2.
1.
5. 8x
3.9 x 9.5
Secure the side panels to the upper fix-
ing rails.
Fitting the thermal insulation (cont.)
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Front panels
3.9 x 9.5
2.
3.
1.
2 mm
3.9 x 9.5
Fully insert the screws into the front
panel top after fitting the boiler tempera-
ture sensor and the other sensors (see
page 13).
Note
Prepare an aperture for the ventilation air
pipe in the front panel when operating
the boiler in balanced flue mode.
Installation instructions for acces-
sories for balanced flue opera-
tion
Fitting the thermal insulation (cont.)
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Thermal insulation mat at the back and back panels
2.
4x
1.
4.
3.
Align the side panels if required to match
the front and back panels. For this, undo
the oval head screws in the top fixing
rails.
Control unit installation
!Please note
Damage to the capillary tubes
can impair the function of the sen-
sors.
Never kink the capillary tubes.
Note
Screws for securing the control unit are
included in the carton containing the con-
trol unit fascia.
Fitting the thermal insulation (cont.)
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6 x 12
2.
3.
1.
Connecting on the heating water side
Note
The Vitocrossal is only suitable for fully
pumped hot water heating systems.
Never install 4-way mixers, overflow
valves or other flow/return bypass devi-
ces.
Never connect heat consumers to the
safety connection.
Install all pipe connections free of load
and torque stresses.
Control unit installation (cont.)
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KR AKVSA
EKOA
AFemale connection for control
equipment R ½ (e.g. minimum
pressure limiter)
E Drain and diaphragm expansion
vessel connection R 1
KOA Condensate drain R ½
KR Boiler return
87 to 142 kW: PN 6 DN 50
186 to 311 kW: PN 6 DN 65
KV Boiler flow
87 to 142 kW: PN 6 DN 50
186 to 311 kW: PN 6 DN 65
SA Safety connection (safety valve
and air vent valve) G 1¼
1. Flush the heating system thor-
oughly.
2. Connect the heating circuits.
Connecting on the heating water side (cont.)
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1. Make the safety connection. 2. Check the connections on the heat-
ing water side for possible leaks.
Permiss. operating pressure: 4 bar
Test pressure: 5.2 bar
Low water indicator (water level lim-
iter)
Protect the boilers against low water lev-
els in accordance with EN 12828. The
minimum pressure limiter (available as
accessory) can be used for this pur-
pose.
Safety valve
Equip the boilers with a safety valve that
is type-tested according to TRD 721 [or
local regulations]. This valve must be
marked according to the system version.
Note
Install all pipe connections free of load
and torque stresses.
!Please note
Unsuitable water quality can
damage the boiler body.
Only fill the boiler with water that
complies with the "Water quality
requirements" (see service
instructions).
Electrical connections and top panel installation
Cables
Note
Boiler water temperature sensor § and
power cable plug fÖ are supplied in the
control unit pack.
Burner cables fA and lÖ are included in
the thermal insulation pack.
!Please note
Damage to the capillary tubes
can impair the function of the sen-
sors.
Never kink the capillary tubes.
Note
Route 230 V cables and LV leads sepa-
rately.
Making the safety connections
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Lift the top of the front panel, and insert
the sensors and the boiler water temper-
ature sensor as far as possible into the
sensor well.
3.9 x 9.5
2.
1.
3.
C
A
B
D
1.
4. 2x
ASensors
BBoiler water temperature sensor
CBurner cable
DConnecting cables
!Please note
Never allow cables to come into
contact with hot components.
Secure all cables with cable ties.
Connections to the control unit base
Installation instructions, boiler control unit
Electrical connections and top panel… (cont.)
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Top panels and covers
2.
6.
A
1.
3.
5.
4.
3.9 x 9.5
3.9 x 30
AType plate (on either the r.h. or l.h.
side)
Connections on the flue gas side
Flue outlet and siphon
Electrical connections and top panel… (cont.)
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1.
3.
1. Insert the boiler flue connection
(accessories) until it bottoms inside
the flue outlet.
Note
Connect the flue outlet to the flue pipe
via the shortest possible run, with a
slight rise (min. 3°). Avoid sharp
bends.
2. Connect the flue system.
Flue outlet system size:
87 to 142 kW: 7 150 mm
186 to 311 kW: 7 200 mm
Installation instructions, flue
system
Note
Make all connections free of load and
torque stresses.
3. Fill the siphon with water and fit it to
the boiler.
Connections on the flue gas side (cont.)
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Condensate drain pipe
Route the condensate drain pipe with a
fall below the anti-flooding level of the
flue gas collector.
Condensate drain A must be able to be
inspected.
Connection (external): 7 19 mm
Neutralising system (if installed)
Install the neutralising system behind the
boiler and connect it with the condensate
drain.
Connect the neutralising system to the
drainage system.
Installation instructions, neutral-
ising system
Connections on the flue gas side (cont.)
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Note
All parts required for installing the burner
are contained in the burner pack.
The hinge bracket is fitted to the l.h. side
of the boiler, but may also be fitted to the
r.h. side.
4.
4x
1.
2.
2x
3.
Tighten the boiler door screws diago-
nally, with a torque of approx. 18 Nm.
Burner installation
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1. Connect the gas supply according to
TRGI 1986/1996 [or local regula-
tions].
aConnect the gas supply accord-
ing to ÖVGW-TR Gas 1996 and
the regionally applicable Build-
ing Regulations.
cConnect the gas supply accord-
ing to SVGW.
Note
According to the [German] Combus-
tion Order, thermally activated shut-
off equipment must be installed in the
gas line.
The installation of a gas filter into the
gas supply line is recommended, if it
has been contaminated (e.g. old
pipes with corrosion products).
Gas supply pressure: 20 mbar
Max. permiss. gas supply pressure:
50 mbar
Gas connection:
87 to 186 kW: R 1
246 and 311 kW: R 1¼
2. Carry out a tightness test.
!Please note
Excessive test pressure may
damage the burner and the
gas valve.
Maximum test pressure
150 mbar. If a higher pres-
sure is required for tightness
tests, separate the burner and
the gas valve from the main
supply pipe (undo the fitting).
3. Vent the gas supply line.
Danger
Escaping gas can lead to
explosions which may result
in serious injury.
Never vent the gas supply line
through the boiler combustion
chamber.
Connecting the burner on the gas supply side
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90
41
A
A
1. Check that the connections "L 1" and
"N" are made correctly at the power
supply of the control unit.
Control unit installation
instructions
Danger
Incorrect core allocation can
cause severe injury and dam-
age the appliance.
Never interchange cores "L
1" and "N".
L1: brown
N: blue
PE: green/yellow
2. Route the burner cables on the hinge
side of the door downwards behind
the r.h. or l.h. cover.
3. Push burner plugs fA and lÖ onto
the MatriX burner.
4. !Please note
Never allow cables to come
into contact with hot compo-
nents.
Secure the burner cables at the top
front panel and at the r.h. or l.h. side
of the cover using cable ties. For this,
use holes A in the panel returns.
When using the stainless steel flue gas
header for two-boiler systems (accesso-
ries):
Installation instructions, flue gas
header (accessories) for two-
boiler systems.
Connecting the burner electrically
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2.
A
3.
1.
OPEN CLOSE
4. 2x
In balanced flue mode, open out aper-
ture A for the ventilation air hose with a
saw.
Fitting the burner hood
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