Viessmann VITOCROSSAL 200 User manual

VIESMANN
Installation instructions
for contractors
Vitocrossal 200
Type CM2
Gas fired condensing boiler with MatriX radiant burner
VITOCROSSAL 200
5592 702 GB 2/2007 Dispose after installation.

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
designed for qualified personnel.
&Work on gas appliances must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
Workingonthesystem
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
Safety instructions
2
5592 702 GB

Preparing for installation.......................................................................... 4
Installation sequence
Boiler positioning and levelling.................................................................... 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 ............................................................................... 10
Connection 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
Connection on the flue gas side .................................................................. 15
&Flue gas connection and siphon ............................................................... 15
&Condensate drain .................................................................................... 16
Burner installation....................................................................................... 16
Burner connection on the gas supply side ................................................... 18
Electrical burner connection........................................................................ 19
Fitting the burner hood................................................................................ 20
Commissioning and adjustment .................................................................. 21
Index
3
5592 702 GB

Clearance dimensions
ABoiler BBurner
CAdjustable anti-vibration boiler
supports (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
andbapply.
Installation instructions flue
gas header and hydraulic sys-
tem connection
Preparing for installation
4
5592 702 GB

!Please note
Damageontheflueoutletcan
lead to flue gas escaping.
Never lift or move the boiler at
theflueoutlet.
Note
A suitable condensate drain (max-
imum 50 mm above floor level) must
be available inside the installation
room, if the boiler is mounted at
ground level.
1. Insert adjustable feet Afrom
above into the bottom rails.
Note
The adjustable feet are supplied in
the accessories pack.
2. Level the boiler. Special founda-
tions are not required.
Note
We recommend the installation of
the boiler on adjustable anti-
vibration supports (accessories).
Insert these from below into the
bottom rails.
Boiler positioning and levelling
5
5592 702 GB

Note
All required components are included
in the thermal insulation carton.
Thermal insulation mats
Note
In case of balanced flue operation,
attach the ventilation pipe before fit-
ting the thermal insulation panels.
Accessory installation instruc-
tions for balanced flue opera-
tion.
Fitting the thermal insulation
6
5592 702 GB

Side panels
Secure the side panels to the upper
fixing rails.
Fitting the thermal insulation (cont.)
7
5592 702 GB

Front panels
Fully insert the screws into the front
panel top after fitting the boiler tem-
perature sensor and the sensors (see
page 13).
Note
Prepare an aperture for the ventilation
pipe in the front panel when operating
the boiler in balanced flue mode.
Accessory installation instruc-
tions for balanced flue opera-
tion.
Fitting the thermal insulation (cont.)
8
5592 702 GB

Thermal insulation mat at the back and back panels
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.
Fitting the thermal insulation (cont.)
9
5592 702 GB

!Please note
Damaged capillaries result in
incorrect sensor functions.
Never kink the capillary tubes.
Note
Screws for securing the control unit
are included in the carton of the con-
trol unit facia.
Connection on the heating water side
Note
The Vitocrossal is only suitable for
pumped hot water heating systems.
Never install four-way mixers, over-
flow valves or other flow/return
bypass devices.
Never connect heat consumers to a
safety connection.
Install all pipe connections free of
load and torque stresses.
Control unit installation
10
5592 702 GB