Viessmann Vitocrossal User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal
Type CRU, 800 to 1000 kW
Gas condensing boiler
VITOCROSSAL
6151133 GB 1/2020 Dispose after installation.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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
■Relevant country-specific safety regu-
lations
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, 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 recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch off the appliance and
let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
Safety instructions
6151133

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!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Safety instructions (cont.)
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1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
■Burner ................................................................................................. 6
■System examples ............................................................................... 6
2. Preparing for installation Clearances and dimensions .................................................................. 7
■Anti-vibration boiler supports .............................................................. 8
Thermal insulation components ............................................................. 8
■Thermal insulation, pack 1 .................................................................. 9
■Thermal insulation, pack 2 .................................................................. 10
3. Installation sequence Siting the combustion chamber module ................................................. 12
■Installation without anti-vibration boiler supports ................................ 12
■Installation with anti-vibration boiler supports ..................................... 12
Attaching the heat exchanger module to the combustion chamber
module ................................................................................................... 13
■Fitting the foot supports to the heat exchanger module ..................... 14
Levelling the combustion chamber and heat exchanger module hori-
zontally ................................................................................................... 15
Connections on the heating water side .................................................. 15
Fitting the thermal insulation .................................................................. 17
Mounting the burner ............................................................................... 18
Attach rails, top and bottom ................................................................... 18
Lay electrical cables on the rails ............................................................ 19
Fit the tie-bars ........................................................................................ 20
Burner electrical connection .................................................................. 20
Fitting the side panels ............................................................................ 21
Fitting the control unit to the top back panel .......................................... 22
Fitting the back panels ........................................................................... 23
Connecting the control unit .................................................................... 24
■Inserting cables and applying strain relief .......................................... 25
■On-site connection to the Vitotronic control unit ................................. 25
■Overview of burner control unit connections ...................................... 26
■Power supply ...................................................................................... 27
Fitting the top panels and control unit cover .......................................... 29
Fitting the front top panel for the control unit ......................................... 30
Fitting the top front panel ....................................................................... 30
Connecting the programming unit .......................................................... 32
Fitting the trap ........................................................................................ 33
Connecting the neutralising system ....................................................... 33
Connections on the flue gas side ........................................................... 34
Fitting the front side panels .................................................................... 35
Connections on the gas side ................................................................. 35
Fitting the front panel ............................................................................. 36
4. Commissioning ................................................................................................................ 37
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, 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.
Burner
Information for the installation of the burner
"MatriX-Disk burner" installation instructions
System examples
Available system examples: See www.viessmann-
schemes.com.
Product information
6151133

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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).
In order to open the burner door to the left, the
hinge pins of the burner door can be swapped to
the other side.
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 two
packs. The following is a list of the components in the
individual packs.
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
0041
0041
Fig. 5
Pos. Part
0001 Thermal insulation mat, front
0002 Thermal insulation jacket, combustion cham-
ber module
0005 Fastening strut
0006 Gas spring
0007 Link, long
0008 Link, short
0009 Rail, short, top left
0010 Rail, short, top right
0011 Rail, top left
0012 Rail, top right
Pos. Part
0013 Tie-bar
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
Pos. Part
0040 Fixings: Spring hooks, edge protection, vari-
ous screws and washers, ball studs, links/
joints and gas springs
0041 Support plate
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 that the spring elements are uniformly loa-
ded, ensure that the installation surface on site is level,
with max. 1 mm in the floor.
1. Lift the combustion chamber module by the lifting
eyes.
2. Arrange the vibration-absorbing boiler supports
centrally under the base rails.
3. A short-term overloading of a boiler support can
arise when setting the boiler down, due to it tilting.
In order to avoid this overloading, distribute square
timbers (□ 35 mm) evenly under the base rails
between the boiler supports as an installation aid.
4. Position the combustion chamber module on vibra-
tion-absorbing boiler supports.
5. Remove the square timbers.
Siting 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
E
D
D
D
D
3.
8x
150 Nm
4x
60 Nm
4.
M 16
Fig. 7
ACombustion chamber module
BHeat exchanger module
CGaskets (included)
DM16 nuts and dished washers (included)
Attaching the heat exchanger module to the combustion chamber module
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Fitting the foot supports to the heat exchanger module
2.
1.
2x
3.
Fig. 8
Note
Foot supports are included with the heat exchanger
module.
Attaching the heat exchanger module to the… (cont.)
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2x
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 module horizontally
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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.
■Boiler return 1 must be connected and receive a
flow equal to at least 15 % of the rated heating
output.
!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.
Fitting the thermal insulation
A
1.
2.
3.
4.
8x
4x
8x
Fig. 11
ABlack side should face outwards
Note
If required, secure the spring hooks to the boiler base.
Connections on the heating water side (cont.)
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"MatriX-Disk burner" installation instructions
Attach rails, top and bottom
A
C
D
M 6 x 10
8x
6.
2. 2x
B
5.
4.
3.
1.
Fig. 12
ARail, top (long)
BRail, top (short)
CRail, bottom (long)
DRail, bottom (short)
ESupport plate
Mounting the burner
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A
2.
B
3.
3x
1.
C
E
D
4.
Fig. 13
ACables 230 V~/400 V~
BExtra low voltage (ELV) leads
CCables with plugs for the burner and programming
unit
DBoiler water temperature sensor
ECables with plugs for connection to Vitotronic con-
trol unit
!Please note
Damage to the connecting cables and sensor
leads (capillaries) causes malfunction.
■The connecting cables and sensor leads must
not come into contact with hot components.
■Never kink the capillary tubes.
!Please note
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
Route LV leads < 42 V separately from cables
> 42 V/230 V~/400 V~. Secure with cable ties.
Lay electrical cables on the rails
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1.
3.
Ø 4.8
2.
4x
Ø 3.5
2x
Ø 4.8
Fig. 14
Burner electrical connection
"MatriX-Disk burner" installation instructions
Fit the tie-bars
6151133