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
Permissible operating pressure 6 bar
VITOCROSSAL 200
5831026 GB 5/2019 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
System examples .................................................................................. 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
Fastenings ............................................................................................. 9
Mounting the burner ............................................................................... 10
■Changing the burner fixture to open on the right (if necessary) ......... 10
■Fitting the control unit module ............................................................ 11
■Mounting the burner ........................................................................... 12
Fitting the thermal insulation and casing ............................................... 13
■Pre-assembling the side panels ......................................................... 13
■Thermal insulation mats ..................................................................... 14
■Fixing rails and retaining brackets ...................................................... 15
■Front of top panel and programming unit ........................................... 16
■Fitting the connecting cables .............................................................. 19
■Back panels ........................................................................................ 25
Connections on the heating water side .................................................. 26
Making the safety connections .............................................................. 27
Connecting the control unit .................................................................... 28
■Connections to the control unit module .............................................. 28
Fitting the top panels and the top back panel ........................................ 28
Connections on the flue gas side ........................................................... 29
■Flue gas connection and trap ............................................................. 29
■Condensate drain pipe ....................................................................... 30
Gas connection ...................................................................................... 30
Commissioning and adjustment ............................................................. 32
Front panel ............................................................................................. 32
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
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.
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.
Disposal of packaging
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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 (not CH)
■Permissible operating pressure 6 bar
■Delivery:
Boiler body on pallet
Thermal insulation, burner, control unit module with
cable harnesses and programming unit packed sep-
arately
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.
System examples
Available system examples: See www.viessmann-
schemes.com.
Product information
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Note
The stated clearances are recommended clearances.
Minimum clearances are indicated in brackets.
600
600
500 (50)
500 (250)
C
A
A B
D
400
E
Fig. 1
ABoiler
BBurner
CBoiler clearance
DClearance required for adjusting the side panels
EBoiler clearance without casing/thermal insulation
C E
75 to 311 kW 40 190
Note
Ensure free access to the control unit box at the back
of the boiler. Do not therefore mount any external
ducts on the back or sides of the boiler.
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
Adjusting screws A 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.
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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The following is a list of the components required for
fastening the individual items.
For easier identification, the components have been
assigned circled numbers.
Pos. Designation Quantity Component
1Spring hook for thermal insulation mats 16
2Connection pin 2
3Location stud 4
4Ball stud 2
5Cable ties 150 x 2.6 31
6Mounting base 20
7Serrated washer 2
8Washer M5 1
9Screw EJOT-Delta-PT 6 x 16 5
qP Allen screw M 6 x 10 10
qQ Round head screw M 5 x 25 TX 25 2
qW Round head screw M 5 x 16 TX 25 1
qE Round head screw M 6 x 16 TX 30 29
qR Self-tapping screw 4.8 x 9.5 TX 40
qT Self-tapping screw 3.5 x 9.5 TX 2
qZ Joint, short 2
qU Joint, long 2
Fastenings
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Changing the burner fixture to open on the right (if necessary)
1.
2.
3.
16
18 Nm
Fig. 4
2. Torque: 18 Nm
Mounting the burner
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Fitting the control unit module
2.
3.
4.
4x
3x
2x 1.
Fig. 5
2. Use 5 screws 9.
3. Use 4 screws qE.
4. Connect the earth cable supplied to the blade ter-
minal contact on the bracket.
The 2 ends of the earth cable are later connected
to the control unit PCB and to the panel that covers
the control unit.
Mounting the burner (cont.)
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Mounting the burner
Example: Burner 75 to 142 kW
1.
16
18 Nm
2.
3.
2x
Fig. 6
1. Hook the burner into the hinge bracket. Secure
with split pin.
!Please note
If the boiler door falls back, it may damage
sensitive parts of the burner and cause inju-
ries.
Carefully insert the burner into the combus-
tion chamber. Do not damage the burner
gauze assembly, electrodes or insulation
block.
Prevent the boiler door from falling back
after it has been opened.
2. Close the burner. Tighten the screws diagonally.
Torque: 18 Nm
3. Check the gap between the boiler front panel and
the hinge bracket so that the boiler door closes
tightly. The gap should be 16 mm ±0.5 mm. 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, e.g. with a
dew point indicator, thermography or flue
gas sensor.
Mounting the burner (cont.)
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Note
All required components are included in the thermal
insulation box.
Pre-assembling the side panels
Fig. 7
1. Lay the side panels for the front, centre and back
on a suitable surface (e.g. packaging materials)
and align.
Note
Observe the cut-outs for the gas line. The cut-outs
must be at the front, at the bottom. See Fig. 9.
2. Secure the guide rails with prefitted sliding profile
to the side panels with 2 x 12 screws qR through
the installation holes.
Fitting the thermal insulation and casing
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Thermal insulation mats
2.
1.
Fig. 8
Secure the thermal insulation jacket and mats at the
front and back with 16 spring hooks 1.
Fitting the thermal insulation and casing (cont.)
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Fixing rails and retaining brackets
1.
3.
2.
A
Fig. 9
ASide panel perforation for gas line
1. Bottom fixing rails: Secure at the front with 2 x 2
screws qE to the base rails, with no protrusion.
2. Top fixing rails: Secure at the front and back with 2
x 2 screws qE; through the middle hole at the front,
and through the first hole at the back.
3. Note
It is easier to install the gas pressure dampers
without the side panels. If necessary, install the
gas springs before mounting the side panels. See
Fig. 10.
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
Note
Do not mount the side panels until the gas springs
have been fitted. See Fig. 9.
1. Screw the ball stud for the gas pressure damper
into the fixing rail from the left. Push the gas pres-
sure damper with piston side onto the ball head.
2. Fit the short links qZ and long links qU with 4
screws qP to the right and left-hand fixing rails.
3. Secure the crossbar to the upper rails of the boiler
using 2 screws qE.
Fitting the thermal insulation and casing (cont.)
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4.
5.
Fig. 11
4. Note
Pre-mount the control unit panel with the program-
ming module and top panel to the base at the front.
Secure the 2 braces to the control unit panel, using
2 screws qR for each.
Insert the ball stud for the gas spring.
5. Secure the control unit panel to the top panel at the
front with 4 screws qE.
Fitting the thermal insulation and casing (cont.)
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8.
7.
6.
A
Fig. 12
6. Position the front of the top panel and secure:
■Secure the gas spring.
■Secure the short and long links to the top panel
using 2 screws qP for each.
7. Insert 1 screw qP halfway into the right-hand side
panel and likewise another into the left-hand side
panel.
8. Pivot the front of the top panel downwards. The
braces (see Fig. 11) should rest on the screws in
the side panel.
Push catch A inwards
Fitting the thermal insulation and casing (cont.)
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Fitting the connecting cables
95 152
53
41 151
100
41
151
53
X5
X5
53
95
152
1
2
72
15A/B
15A/B
72
Fig. 13
1230 V cables
2Extra low voltage (ELV) leads
X5 Power supply, programming unit/control unit
15A/15B Flue gas temperature sensor
41 Burner power supply
53 Flue gas damper, optional
72 CAN bus interface
95 Safety chain
100 Fan control
151 Disconnect safety chain
152 Power supply
Note
Secure the cables to the top rails in such a way that
they do not prevent adjustment of the side panels. See
the diagram below.
Fitting the thermal insulation and casing (cont.)
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Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age. Take the following measures to prevent
wires drifting into the adjacent voltage area:
■Route extra low voltage (ELV) leads < 42 V
and cables > 42 V/230 V~ separately.
Only strip the minimum of insulation from
cables, as close to the terminals as possible,
and bundle them close to the corresponding
terminals.
Secure cables with cable ties.
AH
C
B
D
E
F
G
A
H
F
B
C
E
D
G
K
2
1
Fig. 14 View from above
1230 V cables
2Extra low voltage (ELV) leads
ABoiler water temperature sensor
BBurner power supply
CFlue gas damper, optional
DProgramming unit service interface
EBus interface
FPower supply, control unit programming unit
GCAN bus burner
HFlue gas temperature sensor
KEarthing cable
Fitting the thermal insulation and casing (cont.)
5831026