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
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!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
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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
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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
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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
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!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
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AFemale connection for control
equipment R ½" (e.g. minimum
pressure switch)
E Drain and diaphragm expansion
vessel connection R 1"
KOA Condensate drain R ½"
KR Boiler return
87to142kW: PN6DN50
186to311kW: PN6DN65
KV Boiler flow
87to142kW: PN6DN50
186to311kW: PN6DN65
SA Safety connection (safety valve
and air vent valve) G 1¼"
1. Flush the heating system thor-
oughly.
2. Connect the heating circuits.
Connection on the heating water side (cont.)
11
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1. Make the safety connection.
2. Check the primary connections for
possible leaks.
Permiss. op. pressure: 4 bar
Test pressure: 5.2 bar
Low water indicator (water level limiter)
Protect the boilers against low water
in accordance with EN 12828. For this
purpose, the minimum pressure
switch (available as accessory) can
be used.
Safety valve
Equip boilers with a safety valve that
is type-tested according to TRD 721
[or local regulations]. This valve must
be marked in accordance with the
relevant system.
Note
Install all pipe connections free of
load and torque stresses.
!Please note
Unsuitable water qualities can
result in boiler body damage.
Only fill the boiler with water
that complies with the "Water
quality requirements" (see ser-
vice instructions).
Electrical connections and top panel installation
Cables
Note
Boiler water temperature sensor §
and power supply cable plug fÖ are
included in the control unit package.
Boiler cables fA and lÖ are included
in the thermal insulation pack.
!Please note
Damaged capillaries result in
incorrect sensor functions.
Never kink the capillary tubes.
Note
Route the 230 V cables and LV cables
separately.
Making the safety connections
12
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Lift the top of the front panel, and
insert the sensor and the boiler water
temperature sensor as far as possible
into the sensor well.
ASensor
BBoiler water temperature sensor
CBurner cable
DConnecting cables
!Please note
Never allow cables/leads to
come into contact with hot
components.
Secure all cables/leads with
cable ties.
Connections to the control unit base
Installation instructions, boiler control unit
Electrical connections and top panel installation (cont.)
13
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Top panels and covers
AType plate (optionally on the l.h.
or r.h. side)
Electrical connections and top panel installation (cont.)
14
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Flue gas connection and siphon
1. Insert the boiler flue connection
(accessories) until it bottoms inside
the flue gas connector.
Note
Connect the flue outlet via the
shortest possible run to the chim-
ney stack, maintaining a slight
incline (min. 3°). Avoid sharp
bends.
2. Connect the flue system.
Flue outlet system size:
87 to 142 kW: 7150 mm
186to311kW: 7200 mm
Flue gas system installation
instructions
Note
Make all connections free of load
and torque stresses.
3. Fillthesiphonwithwaterandfitit
to the boiler.
Connection on the flue gas side
15
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Condensate drain
Route the condensate drain with a fall
below the anti-flooding level of the
flue gas header.
The condensate drain Amust be
able to be inspected.
Connection (external): 719 mm
Neutralising system (if installed)
Locate the neutralising system behind
the boiler and connect it with the con-
densate drain.
Connect the neutralising system to
the sewer.
Installation instructions; neu-
tralising system
Burner installation
Note
All parts required for mounting the
burner are contained in the burner
pack.
Thehingebracketisfittedtothel.h.
side of the boiler, but may also be
fitted to the r.h. side.
Connection on the flue gas side (cont.)
16
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Tighten the boiler door screws diag-
onally, with a torque of approx.
18 Nm.
Burner installation (cont.)
17
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1. Connect the mains gas according
to TRGI 1986/1996 [or local regula-
tions].
Note
Accordingtothe[German]Com-
bustion Order, a thermal shut-off
facility must be installed into the
gas supply line.
The installation of a gas filter into
the supply line is recommended, if
the gas line has been contaminated
(e.g. old pipes with corrosion pro-
ducts).
Gas supply pressure: 20 mbar
Max. permissible gas supply pres-
sure: 50 mbar
Gas connection:
87 to 186 kW: R 1"
246 and 311 kW: R 1¼"
2. Carry out a soundness 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 sound-
ness tests, separate the
boiler and the gas train from
the gas supply pipe (undo
the compression fitting).
3. Vent the gas supply pipe.
Danger
Escaping gas can lead to
explosions which may lead
to serious injury.
The gas pipe should not be
vented through the boiler
combustion chamber.
Burner connection on the gas supply side
18
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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 terminations
can cause severe injuries
and damage to the equip-
ment.
Cores"L1"and"N"must
never be interchanged.
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/leads to
come into contact with hot
components.
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 Ain the panel
returns.
When using the stainless steel flue
gas header for two-boiler systems
(accessories):
Installation instructions, flue
gas header (accessories) for
two-boiler systems.
Electrical burner connection
19
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Fitting the burner hood
20
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