Viessmann Vitocrossal 200 CM2 Series User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2, 400 to 620 kW
Gas condensing boiler with MatriX cylinder burner
VITOCROSSAL 200
5833527 GB 6/2018 Dispose after installation.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
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1. Information Disposal of packaging ............................................................................ 4
Key to date of manufacture .................................................................... 4
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Siting conditions ................................................................................................................ 7
3. Preparing for installation Clearance dimensions ........................................................................... 8
Components in thermal insulation package ........................................... 9
■Thermal insulation pack 1 ................................................................... 10
■Thermal insulation pack 2 ................................................................... 11
■Fastenings .......................................................................................... 12
4. Installation sequence Siting and levelling the boiler ................................................................. 13
Fitting the thermal insulation and casing sections ................................. 14
■Thermal insulation jacket for boiler body ............................................ 14
■Front thermal insulation mat ............................................................... 14
■Repositioning the boiler door hinges (if required) ............................... 15
■Closing the boiler door ........................................................................ 15
■Top and bottom rails and side panel supports .................................... 16
■Side panels ......................................................................................... 16
■Crossbar ............................................................................................. 18
Mounting the burner ............................................................................... 19
Fitting and aligning the front side panels ............................................... 20
Burner electrical connection .................................................................. 21
■System power supply ......................................................................... 22
■Routing connecting cables/leads ........................................................ 23
Burner connections on the gas side ...................................................... 24
Fitting further casing sections ................................................................ 25
■Back panels ........................................................................................ 25
■Top panels .......................................................................................... 26
■Front panels and type plate ................................................................ 26
Control unit installation .......................................................................... 27
Connections to the control unit base ..................................................... 28
Connections on the heating water side .................................................. 29
Making the safety connections .............................................................. 29
■Low water indicator (water level limiter) ............................................. 30
■Flash trap ............................................................................................ 30
■Safety valve ........................................................................................ 30
Connections on the flue gas side ........................................................... 30
■Flue outlet ........................................................................................... 30
■Connecting the neutralising system .................................................... 31
Commissioning and adjustment ............................................................. 31
5. Specification ................................................................................................................ 32
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Key to date of manufacture
1 2 43 5 6 7
X X 0 1 2 5 5
Day
Year
Week
Fig. 1
Digits 1 and 2Internal Viessmann information
Digits 3 and 70 and 5 = calendar week 05 = 5th calendar week
Digits 4 and 61 and 5 = year 2015
Digit 52 = 2nd day of the working week
(Monday = 1, Tuesday = 2, etc.)
Example 0501255 corresponds to date of manufacture: 27 January 2015
Disposal of packaging
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Symbols
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Vitocrossal 200, type CM2
■Gas condensing boiler:
–400 to 620 kW rated heating output with modulat-
ing MatriX radiant burner for natural gas E and LL
(also for room sealed operation; accessories
required)
■Permissible operating pressure 6 bar (0.6 MPa)
■Permissible operating temperature up to 95 °C. Per-
missible safety temperature up to 110 °C
■Delivery:
Boiler body on pallet
Thermal insulation, burner, electronics unit with cable
harnesses and programming unit packed separately
Product information
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Use the installation room exclusively for the installation
of the condensing boiler.
Ensure the quality of the combustion air drawn in:
■Combustion air must be free of flammable, explosive
gases and vapours.
■Dust-free, daily mean value < 150 µg/m3 air, Direc-
tive 89/427/EEC
■Combustion air must not be contaminated with halo-
gens or other solvent vapours. In swimming pools in
particular, pay special attention to chlorine and salts
from water treatment.
Siting conditions
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C
A
A
B
b
500
1000
a
500
D
Fig. 2
ABoiler
BBurner
CAdjustable anti-vibration feet (accessories)
DAnti-vibration boiler supports (accessories)
Dimension a: 500 mm
Dimension b: 700 mm
For dimensions a and b when using Viessmann acces-
sories for two-boiler systems, see
Flue gas header installation instructions
100
20
28
M12
Fig. 3 Adjustable anti-vibration feet (accessories)
D
c
d
e
Fig. 4 Anti-vibration boiler supports (accessories)
Clearance dimensions
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Rated heating output kW 400 500 620
Adjustable anti-vibration feet
Permissible load kg 1000
Quantity pce 4
Anti-vibration boiler supports
Permissible load kg 1500 1750
c Front of boiler
Length
Quantity
mm 375 500
pce 2 2
c Back of boiler
Length
Quantity
mm 375 375
pce 2 2
dmm 30
e (unstressed) mm 42
e (stressed) mm 37
Components in thermal insulation package
The thermal insulation and casing are supplied in 2
packs. The following is a list of the components in the
individual packs.
Clearance dimensions (cont.)
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Thermal insulation pack 1
21
7 6 5
qP
9 8
4
3
Fig. 5
1Side panel, left front
2Side panel, left rear
3Thermal insulation jacket
4Side panel, right rear
5Side panel, centre
6Side panel
7Side panel, right front
8Thermal insulation mat, front
9Front panel, top
qP Front panel, bottom
Components in thermal insulation package (cont.)
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Thermal insulation pack 2
qWqQ qE
qTqR qZ qU qI 5
wQ wW wEwPqO
wT wZ
wR
wO
wI
wU
eP
eP
eQ
Fig. 6
5Side panel, centre
qQ Cable channel, lower section
qW Trunking retainer
qE Cable channel, upper section
qR Mounting bracket fascia
qT Mounting bracket
qZ Edge protector
qU Mounting bracket rear panel
qI Side panel, control unit
qO Top panel, front
wP Top panel, centre
wQ Cover
wW Top panel, left rear
wE Top panel, right rear
wR Cross brace
wT Rail, top left
wZ Rail, top right
wU Back panel, top
wI Back panel, centre
wO Back panel, bottom
eP Rail, bottom
eQ Bag of fixing parts
Components in thermal insulation package (cont.)
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Fastenings
The following is a list of the components required for
fastening the individual items.
Bag of fixing parts eQ from thermal insulation pack 2.
For easier identification, the components have been
assigned circled numbers.
Pos. Designation Quantity Component
1Spring hook for thermal insulation mats 10
2Round head screw M6 x 10 22
3Round head screw M6 x 16 4
4Self-tapping screw 4.8 x 9.5 38
5Self-tapping screw 4.8 x 38 5
6Location stud 2
7Spring clip 10
8Round head screw M5 x 25 1
Components in thermal insulation package (cont.)
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Required parts:
■Adjusting screws A are supplied with the boiler.
!Please note
Damage to the flue gas connection can result in
leaks.
Never lift or move the boiler by the flue outlet.
Note
The installation room must be equipped with a suitable
condensate drain (maximum 50 mm above floor level)
if the boiler is installed at ground level.
A
2.
1.
BB C C
Fig. 7
Note
Use holes B and C in the boiler floors to attach lifting
tackle.
1. Insert adjusting screws A into the base rails from
above.
2. Level the boiler horizontally. Special foundations
are not required.
Note
We recommend installing the boiler on adjustable
anti-vibration feet (accessories).
Insert adjustable feet into the base rails from
below.
Siting and levelling the boiler
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Thermal insulation jacket for boiler body
Required parts:
■Thermal insulation jacket 3 from thermal insulation
pack 1
■6 spring hooks 1 from bag of fixing parts eQ from
thermal insulation pack 2
2.
1.
3
Fig. 8
Note
For room sealed operation, attach the ventilation air
pipe before fitting the thermal insulation panels.
Installation instructions for room sealed acces-
sories
Front thermal insulation mat
Required parts:
■Front thermal insulation mat 8 from thermal insula-
tion pack 1
■4 spring hooks 1 from bag of fixing parts eQ from
thermal insulation pack 2
2.
1.
8
Fig. 9
!Please note
If the boiler door falls back this can cause dam-
age and injuries.
Prevent the boiler door from falling back after it
has been opened.
Fitting the thermal insulation and casing sections
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Repositioning the boiler door hinges (if required)
A
B
C
D
B
Fig. 10
The boiler door can be rehung on the opposite side by
moving bolt A to the r.h. side. Sealing frame B
should press centrally onto boiler door gasket D when
the boiler door is closed. If necessary, align mounting
bracket C
Closing the boiler door
1.
Fig. 11
Tighten the six M12 screws in the boiler door evenly
and diagonally. Torque: 40 Nm
Fitting the thermal insulation and casing… (cont.)
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Top and bottom rails and side panel supports
Parts required from thermal insulation pack 2:
■Top left rail wT
■Top right rail wZ
■Bottom rails eP
■Screws from bag of fixing parts eQ
■Connectors eW are supplied with the boiler
5.
1.
4.
16x
16x
2.
AwZ
eP
eW
3.
wT
Fig. 12
5. Loosely fit the supports to the base frame, using
two M 6 x 16 screws for each.
Note
The top rails must be flush at the front (see A).
The base rails must protrude at the back.
Side panels
Parts required from thermal insulation pack 1:
■Centre side panel 5
■Back right side panel 4
■Back left side panel 2
■Side panel 6
Parts required from thermal insulation pack 2:
■Centre side panel 5
■Control unit side panel qI
■Screws from bag of fixing parts eQ
Fitting the thermal insulation and casing… (cont.)
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5.
4.
6.
1.
3.
2.
2
5
6
qI
5
4
Fig. 13
Note
The control unit can be fitted on the left or right.
Mount the control unit side panel on the right or left
accordingly.
Secure the side panels to the top rails with two 4.8
screws for each.
Fitting the thermal insulation and casing… (cont.)
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Crossbar
Parts required from thermal insulation pack 2:
■Cross brace wR
■Screws from bag of fixing parts eQ
1.
wR
Fig. 14
Fitting the thermal insulation and casing… (cont.)
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Note
All parts required for mounting the burner are con-
tained in the burner pack.
6x
4.
1.
2.
3.
A
Fig. 15
AProtective foil sleeve
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
Danger
Protruding side rails can cause impact injuries.
Take care when working; if necessary tempora-
rily hang coloured tape over the side rails.
!Please note
Contamination of the burner gauze assembly
can lead to malfunctions.
When inserting the burner gauze assembly
ensure that no fibres from the thermal insulation
block adhere to the burner gauze assembly.
!Please note
Incorrect installation of the burner gauze assem-
bly can result in contamination of the combus-
tion chamber.
Ensure that the combustion chamber is kept free
of thermal insulation fibres at all times.
Note
To protect the burner gauze assembly, do not remove
the protective foil sleeve until after the burner gauze
assembly has been routed through the boiler door.
1. Insert six M 12 stud bolts into the boiler door.
Mounting the burner
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2. Position the gasket.
3. Position the burner at the boiler door, guiding the
burner gauze assembly carefully through the aper-
ture.
Note
The burner should be fitted by 2 people or with the
help of a lifting aid.
Take care with electrodes and the burner gauze
assembly; do not damage them.
4. Tighten the six M 12 nuts diagonally with a torque
of at least 18 Nm.
5. Undo the six M 12 bolts on the boiler door to open
it.
6. Seal the gap between the burner gauze assembly
and the thermal insulation block of the boiler door
with the flame tube gasket.
Fig. 16
7. Remove burner gauze assembly protector A.
8. Check the electrode gap (see service instructions)
and the surface of the burner gauze assembly for
damage.
9. Close the boiler door and evenly tighten the six
M 12 bolts on the boiler door, working diagonally.
Torque: 40 Nm
Fitting and aligning the front side panels
Parts required from thermal insulation pack 1:
■Front right side panel 7
■Front left side panel 1
Required parts from thermal insulation pack 2 (bag of
fixing parts eQ):
■Fixing clips eE
■Screws
Mounting the burner (cont.)
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