Viessmann Vitocrossal CRU Series User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal
Type CRU, 800 to 1000 kW
Gas condensing boiler
VITOCROSSAL
5833291 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
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
■System examples ............................................................................... 5
2. Preparing for installation Clearances and dimensions .................................................................. 6
■Anti-vibration boiler supports .............................................................. 7
Thermal insulation components ............................................................. 7
■Thermal insulation, pack 1 .................................................................. 8
■Thermal insulation, pack 2 .................................................................. 9
3. Installation sequence Installing the combustion chamber module ........................................... 11
■Installation without anti-vibration boiler supports ................................ 11
■Installation with anti-vibration boiler supports ..................................... 11
Fitting the heat exchanger module to the combustion chamber module 12
■Fitting the supplied foot supports to the heat exchanger module ....... 13
Levelling the combustion chamber and heat exchanger modules ......... 14
Connections on the heating water side .................................................. 14
Fitting the thermal insulation .................................................................. 17
Mounting the burner ............................................................................... 18
■Fitting the intake extension to the burner ........................................... 19
Attaching the top and bottom rails ......................................................... 20
Routing electric cables along the rails ................................................... 21
Fitting the crossbars .............................................................................. 22
Burner electrical connection .................................................................. 23
Fitting the side panels ............................................................................ 24
Attaching the control unit panel to the front top panel ........................... 25
Fitting the top front panel ....................................................................... 25
Connecting the programming unit .......................................................... 27
Fitting the control unit to the top back panel .......................................... 28
Attaching the back panels ...................................................................... 29
Connecting the control unit .................................................................... 30
■Inserting cables and applying strain relief .......................................... 31
■On-site connections at the Vitotronic control unit ............................... 31
■Overview of electrical connections, burner control unit ...................... 32
■Power supply ...................................................................................... 33
Fitting the top panels and control unit cover .......................................... 35
Fitting the trap ........................................................................................ 36
Connecting the neutralising system ....................................................... 36
Connections on the flue gas side ........................................................... 36
Fitting the front side panels .................................................................... 38
Connections on the gas side ................................................................. 39
Fitting the front panel ............................................................................. 40
4. Commissioning ................................................................................................................ 41
5. Keyword index ................................................................................................................ 42
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
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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, type CRU
■Gas condensing boiler, 800 kW and 1000 kW rated
heating output with modulating MatriX-Disk burner
for natural gas E and natural gas LL
■Permissible operating pressure for the heating sys-
tem: 6 bar/0.6 MPa.
System examples
For available system examples, see www.viessmann-
schemes.com
Intended use (cont.)
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Note
The stated clearances are recommended clearances.
Minimum clearances are indicated in brackets.
A
B
C
D
700
(300)
a
b
810
200
(100)
600
Fig. 1
ABoiler
BAnti-vibration boiler supports
CBurner
DBurner door opens to the right (delivered condi-
tion).
The hinge pins of the burner door can be reposi-
tioned so that the burner door opens to the left.
Vertical flue gas pipework
500
(300)
Fig. 2
Note
If routing the flue gas vertically, allow space for work-
ing on the control unit.
Dimension a b
Clearance Minimum
clearance
Recommen-
ded clearance
Minimum
clearance
Recommen-
ded clearance
Right-hand burner door opens to the right.
And
Left-hand burner door opens to the left.
400 500 910 1010
Right-hand burner door opens to the left.
Or
Left-hand burner door opens to the right.
910 1010 400 500
Clearances and dimensions
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Anti-vibration boiler supports
c
e
d
Fig. 3
Permissible load kg 2970
c Boiler front
■Length mm 125
■Quantity pce 2
Boiler back
■Length mm 667
■Quantity pce 2
d■Boiler front mm 30
■Boiler back mm 100
e■Spring elements, unloa-
ded
mm 41
■Spring elements, loa-
ded
mm 38-39
Thermal insulation components
The thermal insulation and casing are supplied in 2
packs. The following is a list of the components in the
individual packs.
Note
The position numbers correspond to the "Casing
assembly" parts list in the service instructions.
Clearances and dimensions (cont.)
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Thermal insulation, pack 1
0031
0003
0028
0027
0030
0029
0038
0039
0019
0037
0036
0035
0032 0033
0034
0039
0038
0004
Fig. 4
Pos. Part
0003 Thermal insulation jacket, heat exchanger
module
0004 Thermal insulation mat, heat exchanger mod-
ule
0019 Side panel, front left
0027 Front panel
0028 Control unit panel
0029 Top panel, front
0030 Top panel, left
0031 Top panel, right
Pos. Part
0032 Top panel, centre
0033 Top panel, back
0034 Back panel, top
0035 Control unit cover
0036 Back panel, centre
0037 Back panel, bottom
0038 Viessmann logo
0039 Vitocrossal logo
Thermal insulation components (cont.)
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Thermal insulation, pack 2
0024
0020
0015 0025
0021
0013 0014
0010
0013
0013
0013
0009
0001
0012
0017
0022
0018
0011
0008
0008
0007
0007
0006
0006
0005
0005
0023
0026
0016
0040
0002
Fig. 5
Pos. Part
0001 Thermal insulation mat, front
0002 Thermal insulation jacket, combustion cham-
ber module
0005 Fixing strut
0006 Gas spring
0007 Joint, long
0008 Joint, short
0009 Rail, short, top left
0010 Rail, short, top right
0011 Rail, top left
0012 Rail, top right
Pos. Part
0013 Crossbar
0014 Distribution panel
0015 Extension, bottom left
0016 Extension, bottom right
0017 Rail, bottom left
0018 Rail, bottom right
0020 Centre side panel 1, left
0021 Centre side panel 2, left
0022 Side panel, back left
0023 Side panel, front right
Thermal insulation components (cont.)
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Pos. Part
0024 Centre side panel 1, right
0025 Centre side panel 2, right
0026 Side panel, back right
0040 Fixings: Spring hooks, edge protectors, vari-
ous screws and washers, ball studs, links and
gas springs
Thermal insulation components (cont.)
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Installation without anti-vibration boiler supports
1. Position a plate, e.g. a flat steel strip, underneath
the adjusting screws to distribute the load evenly.
2.
Fig. 6
Installation with anti-vibration boiler supports
To ensure the spring elements bear an equal load, pro-
vide a level installation area on site, with max. 1 mm
unevenness in the floor.
1. Lift the combustion chamber module by the lifting
eyes.
2. Position the anti-vibration boiler supports centrally
under the base rails.
3. When setting the boiler down less than square on,
a boiler support can temporarily become overloa-
ded.
To prevent such overloading, position timbers
(ø 35 mm) under the base rails, evenly placed
between the boiler supports, to act as installation
aids.
4. Position the combustion chamber module on the
anti-vibration boiler supports.
5. Remove the timbers.
Installing the combustion chamber module
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!Please note
Scratches inside the combustion chamber or on
components that come into contact with flue gas
can lead to corrosion damage.
Never place tools or other objects inside the
combustion chamber.
1. Lift the heat exchanger module by the lifting eyes.
C
B
A
2.
C
A
B
C
C
D
D
D
D
3.
10x
110 Nm
4x
60 Nm
4.
Fig. 7
ACombustion chamber module
BHeat exchanger module
CGaskets (included)
DNuts M16 and dished washers (included)
Fitting the heat exchanger module to the combustion chamber module
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Fitting the supplied foot supports to the heat exchanger module
2.
1.
2x
3.
Fig. 8
Fitting the heat exchanger module to the… (cont.)
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6x
Fig. 9
Connections on the heating water side
Note
The boiler is only suitable for fully pumped hot water
heating systems.
Levelling the combustion chamber and heat exchanger modules
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A
B
C
D
E
F
G
H
Fig. 10
AFemale connection for control equipment: R ½
BBoiler flow: PN 6, DN 100 with sensor well for
boiler water temperature sensor
CFemale connection for pressure limiter: R ½
DSafety connection (safety valve): R 2
EBoiler return 2: PN 6, DN 100
FBoiler return 1: PN 6, DN 100
GDrain outlet: R 1¼
HCondensate drain: R ½
1. Thoroughly flush the heating system.
Connections on the heating water side (cont.)
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2. Connect the hydraulic lines.
System with 1 heating circuit:
■Connect the heating return to boiler return 1.
System with 2 heating circuits:
■Connect the heating circuit with the higher tem-
perature level to boiler return 2.
■Connect at least 15 % of the rated heating output
to boiler return 1.
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
3. Seal any unused connections.
Note
Never connect a heat consumer to connector D
(safety connection).
4. Check the hydraulic connections for tightness.
!Please note
Unsuitable water quality can damage the
boiler body.
Only fill the boiler with water that complies
with the "Water quality requirements": See
"Vitocrossal, type CRU" service instructions
5. Thermally insulate the hydraulic lines.
Connections on the heating water side (cont.)
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A
1.
2.
3.
5.
4.
8x
4x
8x
8x
Fig. 11
ABlack side outwards
Note
If required, secure the spring hooks to the boiler base.
Fitting the thermal insulation
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A1.
2x
2.
6x
40 Nm
3.
120 kg!
Fig. 12
ALifting eye
Danger
Incorrect handling of the 120 kg burner can
cause injury.
Move the burner with suitable auxiliary equip-
ment e.g. a crane. Use the lifting eye on the
burner.
!Please note
Mechanical damage to delicate components will
impair the burner function.
Carefully insert the burner into the combustion
chamber. Do not damage the burner gauze
assembly, electrodes or insulation block.
Mounting the burner
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Fitting the intake extension to the burner
A
2.
1.
3.
Fig. 13
ARetaining bracket
!Please note
Mechanically loaded ventilation air pipework can
lead to leaks and appliance damage.
Secure the intake extension free of load and tor-
que stress.
Mounting the burner (cont.)
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A
C
D
B
4.
1.
3.
M 6 x 10
2.
Fig. 14
ARail, top (long)
BRail, top (short)
CRail, bottom (long)
DRail, bottom (short)
Attaching the top and bottom rails
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