Viessmann Vitocrossal User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal
Type CRU, 800 to 1000 kW
Gas condensing boiler
VITOCROSSAL
5816716 GB 1/2018 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
2. Preparing for installation Clearance dimensions ........................................................................... 6
Thermal insulation components ............................................................. 6
■Thermal insulation pack 1 ................................................................... 7
■Thermal insulation pack 2 ................................................................... 8
3. Installation sequence Siting the boiler ...................................................................................... 10
Assembling the heat exchanger and combustion chamber module ...... 11
■Mounting the foot supports ................................................................. 12
Connections on the heating water side .................................................. 13
Fitting the thermal insulation .................................................................. 14
Mounting the burner ............................................................................... 15
■Fitting the intake extension to the burner ........................................... 16
Attaching the top and bottom rails ......................................................... 17
Routing electric cables along the rails ................................................... 18
Fitting the crossbars .............................................................................. 19
Burner electrical connection .................................................................. 20
■Routing electrical cables to the burner ............................................... 20
■Connecting the burner cables ............................................................. 21
Fitting the side panels ............................................................................ 22
Attaching the control unit panel to the front top panel ........................... 23
Attaching the front top panel with programming unit ............................. 24
Attaching the control unit to the upper back panels ............................... 27
Attaching the back panels ...................................................................... 28
Connecting the control module .............................................................. 29
■Plug-in connection diagram for the power supply box ........................ 31
Fitting the top panels and control unit cover .......................................... 32
Fitting the trap ........................................................................................ 32
Connecting the neutralising system ....................................................... 33
Connections on the flue gas side ........................................................... 33
Fitting the front side panels .................................................................... 34
Connections on the gas side ................................................................. 35
Fitting the front panel ............................................................................. 36
4. Commissioning ................................................................................................................ 37
Index
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Disposal of packaging
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.
Intended use (cont.)
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Note
The hinge pins can be repositioned so that the boiler
door opens to the left.
700
600
(300)
500 (50)
500 (50)
200 (100)
810
A B
C
Fig. 1
ABoiler
BBurner
CAnti-vibration boiler supports
Dimensions in brackets are minimum clearances.
500
(300)
Fig. 2 Clearance for vertical flue gas pipework (min-
imum dimension in brackets)
Note
With vertical flue gas routing, take into consideration
the space required for working on the control unit.
c
e
d
Fig. 3
Anti-vibration boiler supports
Permissible load kg 2970
c front, length/number mm/pce 125/2
c back, length/number mm/pce 667/2
d front/back mm 30/100
e (unstressed) mm 41
e (stressed) 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 "Thermal
insulation assembly" parts list in the service instruc-
tions.
Clearance dimensions
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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, back
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 Front thermal insulation mat
0002 Thermal insulation jacket, combustion cham-
ber module
0005 Fixing strut
0006 Gas strut
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
0024 Centre side panel 1, right
Thermal insulation components (cont.)
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Pos. Part
0025 Centre side panel 2, right
0026 Side panel, back right
0040 Fixings: Spring hooks, edge protection, vari-
ous screws and washers, ball studs, joints
and gas struts
Thermal insulation components (cont.)
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2.
1.
Fig. 6
Installation without anti-vibration boiler supports
Position a plate, e.g. a flat steel strip, underneath the
adjusting screws to distribute the load evenly.
Installation with anti-vibration boiler supports
On site, provide a level supporting surface for the
boiler. Position the boiler on the anti-vibration boiler
supports. Any unevenness in the floor must be no
greater than 1 mm to ensure that the spring elements
are loaded evenly.
Position the boiler supports underneath the boiler by
placing them centrally under the base rails.
When setting the boiler down less than square on, a
boiler support can temporarily be overloaded. To aid
installation, support the boiler on timbers (□ 35 mm).
Distribute the timbers evenly under the boiler supports.
Siting the boiler
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A
B
C
3.
B
A
2.
2.
1.
3.
C
Fig. 7
ACombustion chamber module
BHeat exchanger module
CGaskets are included.
!Please note
Scratches on parts that come into contact with
flue gas can corrode.
Never place tools or other objects inside the
combustion chamber.
Note
Lift the heat exchanger module by the lifting eyes.
1. Position the heat exchanger module on the com-
bustion chamber module.
2. Insert the gaskets at the upper and lower flange.
Tighten the screws and nuts diagonally.
Torque: 110 Nm
3. Tighten the connections diagonally using the M 16
nuts supplied and 2 dished washers.
Torque: 60 Nm
Assembling the heat exchanger and combustion chamber module
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Mounting the foot supports
2.
3.
1.
Fig. 8
Note
Foot supports and adjustable feet are supplied with the
boiler.
1. Screw the adjustable feet fully onto the foot sup-
ports.
2. Secure the foot supports with screws.
3. Wind out the adjustable feet until the heat
exchanger module is sufficiently supported.
4. Level the combustion chamber and heat
exchanger module horizontally using the adjusta-
ble feet.
Assembling the heat exchanger and combustion… (cont.)
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AB
C
D
E
F
G
H
Fig. 9
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
Danger
There is a risk of injury when working on pres-
surised components.
Only open the connections on the heating water
side after the boiler has been depressurised.
Note
■The boiler is only suitable for fully pumped hot water
heating systems.
■Install all pipe connections free of load and torque
stress.
1. Thoroughly flush the heating system.
2. Make all necessary connections.
Connection 1 heating circuit
■Connect the heating return to boiler return 1.
Connection 2 heating circuits
■Connect the heating circuit with the higher tem-
perature level to boiler return 2.
■Connect at least 15 % of the boiler heating out-
put to boiler return 1.
Seal unused test ports.
Note
Never connect heat consumers to the safety con-
nector.
Connections on the heating water side
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!Please note
Unsuitable water quality can damage the boiler
body.
Only fill the boiler with water that complies with
the "Water quality requirements" (see service
instructions).
Fitting the thermal insulation
12x
A
1.
2.
3.
5.
4.
Fig. 10
ABlack side outwards
Note
Attach 4 spring hooks under the thermal insulation
jacket. Use 8 spring hooks each for the front and rear
thermal insulation mat. If required, secure spring hooks
to the boiler floor.
3. Connect the thermal insulation mat with an over-
lap.
Connections on the heating water side (cont.)
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A1.
2x
2.
3.
6x
Fig. 11
Danger
The burner weighs 120 kg and may cause inju-
ries if handled incorrectly.
Use suitable equipment, e.g. a crane, to move
the burner. Use lifting eye A 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.
3. Tighten the screws diagonally. Torque: 40 Nm
Mounting the burner
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Fitting the intake extension to the burner
2.
1.
3.
Fig. 12
3. Secure the intake extension in place with the
mounting plate. !Please note Mechanically loaded supply air pipes lead to
leaks and appliance damage.
Ensure the intake extension on the burner is
free of load and torque stress.
Mounting the burner (cont.)
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A
C
D
B
1.
2.
4.
3.
Fig. 13
ARail, top (long)
BRail, top (short)
CRail, bottom (long)
DRail, bottom (short)
Note
Use M 6 screws.
2. Loosely screw 2 screws into each boiler base rail.
4. Attach the rail to the screws of the boiler base rail.
Tighten the screws.
Attaching the top and bottom rails
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4.
A
2.
B
3.
3x
1.
Fig. 14
A230/400 V∼ cables
BLV leads
4. Push the boiler water temperature sensor into the
sensor well as far as it will go and secure with clip.
!Please note
Damaged capillary tubes will result in faulty
sensor function.
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 and cables > 42 V/230
V~/400 V~ separately. Secure with cable ties.
Routing electric cables along the rails
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1.
2.
3.
Fig. 15
1. Place 4 crossbars on the rails.
Fasten each to the rails with 4 screws (7 4.8).
2. Attach the distribution panel to the rear crossbar
with 2 screws (7 4.8).
3. Secure the power supply box to the distribution
panel with 4 screws (7 3.5).
Fitting the crossbars
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Routing electrical cables to the burner
4x
Fig. 16
Note
Attach the cables to the front crossbar using cable
retainers.
Do not tighten the cable retainers until the burner
cables are connected.
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
Route LV leads and power cables (230/400 V∼)
separately. Secure with cable ties.
Burner electrical connection
5816716