Viessmann VITOCROSSAL 200 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2C, 75 to 311 kW
Gas condensing boiler
For open flue and room sealed operation
VITOCROSSAL 200
5799212 GB/en 12/2017 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
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
Conversion for other countries ............................................................... 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
3. Installation sequence Siting and levelling the boiler ................................................................. 7
■Removing the base frame for handling (if necessary) ........................ 8
Mounting the burner ............................................................................... 9
■Changing the burner fixture to open on the right (if necessary) ......... 9
■Mounting the burner ........................................................................... 10
Fitting the electronics unit ...................................................................... 11
Fitting the thermal insulation and casing ............................................... 12
■Thermal insulation mats ..................................................................... 12
■Pre-assembling the side panels ......................................................... 13
■Fixing rails and retaining brackets ...................................................... 14
■Front of top panel and programming unit ........................................... 15
■Fitting the connecting cables .............................................................. 18
■Back panels ........................................................................................ 23
Connections on the heating water side .................................................. 24
Making the safety connections .............................................................. 25
Connecting the control unit .................................................................... 25
■Connections to the electronics unit ..................................................... 25
Fitting the top panels and the top back panel ........................................ 26
Connections on the flue gas side ........................................................... 27
■Flue gas connection and trap ............................................................. 27
■Condensate drain pipe ....................................................................... 28
Gas connection ...................................................................................... 28
Commissioning and adjustment ............................................................. 30
Front panel ............................................................................................. 30
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.
Symbols
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.
Disposal of packaging
5799212

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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.
Product information
Vitocrossal 200, type CM2C
■Gas condensing boiler:
–75 to 142 kW rated heating output with modulating
MatriX radiant burner for natural gas E and LL
–186 to 311 kW rated heating output with modulat-
ing MatriX cylinder burner for natural gas E, LL and
LPG P
■Permissible operating pressure 6 bar
■Delivery:
Boiler body on pallet
Thermal insulation, burner, electronics unit with cable
harnesses and programming unit packed separately
Conversion for other countries
The Vitocrossal 200 may only be delivered to the
countries specified on the type plate. For deliveries to
other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
Intended use (cont.)
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600
600
500 (50)
500 (250)
C
500
C
A
A B
D
400
Fig. 1
ABoiler
BBurner
CDimensions for installation as a two-boiler system
with Viessmann accessories:
Installation instructions for flue gas header and
hydraulic system connection
DClearance for adjusting the side panels
Dimensions in brackets are minimum clearances.
Clearance dimensions
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!Please note
Damage to the flue gas connection can result in
leaks.
Never lift or move the boiler by the flue gas con-
nection.
Information on handling
Hook lifting gear for transport by crane into the holes in
the front and back panel of the boiler.
Note
A suitable condensate drain must be available in the
installation room. If the boiler is installed at ground
level, the condensate drain must be no more than
50 mm above floor level. Otherwise install a conden-
sate removal pump.
2.
A
1.
Fig. 2
1. Insert adjusting screws A into the base rails from
above.
The adjusting screws are supplied in the accessory
pack.
Recommendation:
Position the boiler on adjustable anti-vibration feet
(accessories). Insert adjustable feet into the base
rails from below.
2. Level the boiler horizontally. Special foundations
are not required.
Siting and levelling the boiler
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Removing the base frame for handling (if necessary)
If necessary, the base frame can be removed for han-
dling.
4x
2.
1.
Fig. 3
Danger
If the boiler is not secured, it can slide off the
base frame and cause injury.
Secure the boiler body. Wear safety boots.
1. Undo the 4 screws and remove.
2. Lift the boiler off the base frame.
!Please note
If the drain connector is left unprotected, it
can be damaged while the boiler is being
transported and set down without the base
frame.
Set the boiler down carefully; place timber
below if necessary.
3. Fit the base frame in reverse order.
Torque for fixing screws 40 Nm
Siting and levelling the boiler (cont.)
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Changing the burner fixture to open on the right (if necessary)
1.
2.
16
18 Nm
Fig. 4
1. Remove the four M10 nuts with washers and the
hinge bracket.
2. Attach the hinge bracket to the threaded pins on
the right-hand side in reverse order. Adjust the gap
between the boiler front panel and the hinge
bracket to 16 ± 0.5 mm.
Torque: 18 Nm
Mounting the burner
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Mounting the burner
1.
16
18 Nm
2.
3.
Fig. 5
1. Hook the burner onto the hinge bracket and secure
with the split pin.
!Please note
Mechanical damage to delicate components
will impair the burner function.
Carefully insert the burner into the combus-
tion chamber. Do not damage the burner
gauze assembly, electrodes or insulation
block.
2. Close the burner. Tighten the screws diagonally.
Torque: 18 Nm
3. Check that the gap between the boiler front panel
and the hinge bracket is 16 mm ±0.5 mm, so that
the boiler door closes tightly. Correct if necessary
using the 4 nuts.
Torque: 18 Nm
Danger
Leaks from the boiler door can result in poi-
soning through escaping flue gas.
Check the boiler door for leaks. For exam-
ple, use a dew point indicator, thermal imag-
ing or flue gas sensor.
Mounting the burner (cont.)
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1.
2.
3.
4.
5.
Fig. 6
1. Fit the rear thermal insulation mat.
2. Secure the electronics unit to the bracket.
3. Secure the bracket with electronics unit to the
upper rails at the back of the boiler.
4. Connect the earth cable of the electronics unit to
the blade terminal contacts in the bracket.
5. Connect the earth cable supplied for the cover
panel to the blade terminal contacts in the bracket.
Fitting the electronics unit
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Note
All required components are included in the thermal
insulation box.
Thermal insulation mats
2.
1.
3.
Fig. 7
Secure all thermal insulation mats with spring hooks.
Fitting the thermal insulation and casing
5799212

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Pre-assembling the side panels
Fig. 8
1. Lay the side panels for the front, centre and back
on a suitable surface (e.g. packaging materials)
and align.
2. Secure the guide rails (with sliding profile) to the
side panels with screws through the installation
holes.
Fitting the thermal insulation and casing (cont.)
5799212

14
Fixing rails and retaining brackets
1.
3.
2.
Fig. 9
1. Bottom fixing rails: Secure with screws to the base
rails, flush with the front.
2. Top fixing rails: Secure at the front with screws
through the front slot.
3. Position the pre-assembled side panels with the
guide rails at the bottom, then hook onto the tabs
in the fixing rails at the top.
Fitting the thermal insulation and casing (cont.)
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Front of top panel and programming unit
3.
1.
2.
Fig. 10
01. Attach the gas spring to the right or left-hand fixing
rail.
02. Fit the short and long links, each with two M6
screws, to the right and left-hand fixing rails.
03. Secure the crossbar to the upper rails of the boiler
using two M6 screws.
Fitting the thermal insulation and casing (cont.)
5799212

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6.
4.
5.
Fig. 11
04. Insert the programming unit into the opening in the
control unit panel from the inside.
Secure the programming unit with 4 screws
Ø 4.8 mm.
05. Secure 2 braces to the control unit panel, each
with 2 screws Ø 4.8 mm.
06. Secure the control unit panel to the front of the top
panel with two screws Ø 4.8 mm and four M6
screws.
Fitting the thermal insulation and casing (cont.)
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7.
10.
9.
8.
Fig. 12
07. Carefully push open the right and left-hand sliders
on the programming unit.
08. Position the front of the top panel and secure:
■Secure the gas spring.
■Secure the short and long links, each with two
M6 hexagon socket screws.
09. Insert one M6 screw halfway into the right-hand
side panel and likewise another into the left-hand
side panel.
10. Pivot the front of the top panel downwards. The
braces should rest on the screws in the side pan-
els.
Fitting the thermal insulation and casing (cont.)
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Fitting the connecting cables
A
B
95 152
53
41 151
Fig. 13
1. Secure data cables A to the top left-hand fixing
rail using the cable ties provided, as shown in the
diagram.
See the following diagram for the spacing between
cable ties.
2. Secure 230 V cables B to the top right-hand fixing
rail using the cable ties provided, as shown in the
diagram.
See the following diagram for the spacing between
cable ties.
Note
Secure the cables in such a way that they do not
prevent adjustment of the side panels.
Fitting the thermal insulation and casing (cont.)
5799212

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Fig. 14
Fitting the thermal insulation and casing (cont.)
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Inserting the plugs into the gas burner control unit and burner
95
152
53
3A
3B 15A 15B
Fig. 15
1. Insert the data cable plugs as shown in the dia-
gram.
2. Insert the sensor lead plugs as shown in the dia-
gram.
3. Insert the 230 V cable plugs as shown in the dia-
gram.
!Please note
Cables can be damaged by high temperatures.
Prevent contact with hot components.
Fitting the thermal insulation and casing (cont.)
5799212