Viessmann VITOCROSSAL 200 Installation Instructions Manual
Type cm2c
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Also See for VITOCROSSAL 200:
- Service instructions manual (96 pages) ,
- Service instructions for contractors (88 pages) ,
- Instructions manual (72 pages)
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Table of Contents
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Summary of Contents for Viessmann VITOCROSSAL 200
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Page 1: Installation Instructions
VIESMANN Installation instructions for contractors Vitocrossal 200 Type CM2C, 75 to 311 kW Gas condensing boiler For open flue and room sealed operation Permissible operating pressure 6 bar VITOCROSSAL 200 Dispose after installation. 5831026 GB 5/2019... -
Page 2: Safety Instructions
Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk of injury. Details identified by the word "Note" contain additional information. Please note This symbol warns against the risk of material losses and environmental pollution. -
Page 3: Table Of Contents
Index Information Disposal of packaging ................Symbols ....................Intended use ..................Product information ................Conversion for other countries ............... System examples .................. Preparing for installation Clearance dimensions ................Installation sequence Siting and levelling the boiler ..............Removing the base frame for handling (if necessary) ......■... -
Page 4: Information Disposal Of Packaging
Disposal of packaging Please dispose of packaging waste in line with statu- tory regulations. Symbols Symbol Meaning Reference to other document containing further information 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... -
Page 5: Product Information
Conversion for other countries The Vitocrossal 200 may only be delivered to the countries specified on the type plate. For deliveries to other countries, approved contractors must arrange individual approval on their own initiative and in accordance with the law of the country in question. -
Page 6: Preparing For Installation Clearance Dimensions
Clearance dimensions Note The stated clearances are recommended clearances. Minimum clearances are indicated in brackets. 500 (50) 500 (250) Fig. 1 Boiler Clearance required for adjusting the side panels Burner Boiler clearance without casing/thermal insulation Boiler clearance 75 to 311 kW Note Ensure free access to the control unit box at the back of the boiler. -
Page 7: Installation Sequence Siting And Levelling The Boiler
Siting and levelling the boiler Please note Note Damage to the flue gas connection can result in A suitable condensate drain must be available in the leaks. installation room. If the boiler is installed at ground Never lift or move the boiler by the flue gas con- level, the condensate drain must be no more than nection. -
Page 8: Removing The Base Frame For Handling (If Necessary)
Siting and levelling the boiler (cont.) Removing the base frame for handling (if necessary) If necessary, the base frame can be removed for han- Danger dling. If the boiler is not secured, it can slide off the base frame and cause injury. Secure the boiler body. -
Page 9: Fastenings
Fastenings The following is a list of the components required for fastening the individual items. For easier identification, the components have been assigned circled numbers. Pos. Designation Quantity Component Spring hook for thermal insulation mats Connection pin Location stud Ball stud Cable ties 150 x 2.6 Mounting base Serrated washer... -
Page 10: Mounting The Burner
Mounting the burner Changing the burner fixture to open on the right (if necessary) 18 Nm Fig. 4 2. Torque: 18 Nm... -
Page 11: Fitting The Control Unit Module
Mounting the burner (cont.) Fitting the control unit module Fig. 5 2. Use 5 screws 4. Connect the earth cable supplied to the blade ter- minal contact on the bracket. The 2 ends of the earth cable are later connected 3. -
Page 12: Mounting The Burner
Mounting the burner (cont.) Mounting the burner Example: Burner 75 to 142 kW 18 Nm Fig. 6 1. Hook the burner into the hinge bracket. Secure 3. Check the gap between the boiler front panel and with split pin. the hinge bracket so that the boiler door closes tightly. -
Page 13: Fitting The Thermal Insulation And Casing
Fitting the thermal insulation and casing Note All required components are included in the thermal insulation box. Pre-assembling the side panels Fig. 7 1. Lay the side panels for the front, centre and back 2. Secure the guide rails with prefitted sliding profile on a suitable surface (e.g. -
Page 14: Thermal Insulation Mats
Fitting the thermal insulation and casing (cont.) Thermal insulation mats Fig. 8 Secure the thermal insulation jacket and mats at the front and back with 16 spring hooks... -
Page 15: Fixing Rails And Retaining Brackets
Fitting the thermal insulation and casing (cont.) Fixing rails and retaining brackets Fig. 9 Side panel perforation for gas line 1. Bottom fixing rails: Secure at the front with 2 x 2 3. Note screws to the base rails, with no protrusion. It is easier to install the gas pressure dampers without the side panels. -
Page 16: Front Of Top Panel And Programming Unit
Fitting the thermal insulation and casing (cont.) Front of top panel and programming unit Fig. 10 Note Do not mount the side panels until the gas springs have been fitted. See Fig. 9. 1. Screw the ball stud for the gas pressure damper 3. - Page 17 Fitting the thermal insulation and casing (cont.) Fig. 11 4. Note 5. Secure the control unit panel to the top panel at the Pre-mount the control unit panel with the program- front with 4 screws ming module and top panel to the base at the front. Secure the 2 braces to the control unit panel, using 2 screws for each.
- Page 18 Fitting the thermal insulation and casing (cont.) Fig. 12 6. Position the front of the top panel and secure: 8. Pivot the front of the top panel downwards. The ■ Secure the gas spring. braces (see Fig. 11) should rest on the screws in ■...
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Page 19: Fitting The Connecting Cables
Fitting the thermal insulation and casing (cont.) Fitting the connecting cables 15A/B 15A/B Fig. 13 230 V cables CAN bus interface Extra low voltage (ELV) leads Safety chain Power supply, programming unit/control unit Fan control 15A/15B Flue gas temperature sensor Disconnect safety chain Burner power supply Power supply... - Page 20 Fitting the thermal insulation and casing (cont.) Danger Incorrect wiring can lead to serious injury from electrical current and result in appliance dam- age. Take the following measures to prevent wires drifting into the adjacent voltage area: ■ Route extra low voltage (ELV) leads < 42 V and cables >...
- Page 21 Fitting the thermal insulation and casing (cont.) Fig. 15 Control unit Power supply, burner 41 Power supply, programming unit X5 Flue gas damper, optional 53 CAN bus burner 72 Programming unit service interface Earthing cable Bus interface Safety chain Insert the plug into the control unit as shown in the dia- Further interfaces gram.
- Page 22 Fitting the thermal insulation and casing (cont.) Inserting the plugs into the gas burner control unit and burner Fig. 16 3A/3B Boiler water temperature sensor Safety chain 15A/15B Flue gas temperature sensor Fan control Flue gas damper, optional Mains voltage CAN bus burner...
- Page 23 Fitting the thermal insulation and casing (cont.) Please note Connection diagram – control cables Cables can be damaged by high temperatures. Service instructions Prevent contact with hot components. Bundle cables and secure with cable ties. Inserting the plugs into the programming unit Fig.
- Page 24 Fitting the thermal insulation and casing (cont.) Inserting the plugs into the control unit module and at the back of the boiler 15A/15B Fig. 18 1. Insert the data cable plugs as shown in the dia- 3. Guide all cables in through the base of the control gram.
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Page 25: Back Panels
Fitting the thermal insulation and casing (cont.) Back panels Fig. 19 1. Secure the right and left-hand retaining rails to the 5. Align the back panels. top and bottom fixing rails using 2 screws Check whether the seal of the control unit module each. -
Page 26: Connections On The Heating Water Side
Connections on the heating water side SA/KR2 Fig. 20 Fitting assembly connection (installation position KOA Condensate drain with trap R ½ towards burner) Boiler return Safety valve or safety equipment block KR2 Boiler return 2 (subject to order) Boiler flow 2nd boiler return Drain and expansion vessel connection R 1 Safety connection G... -
Page 27: Making The Safety Connections
Connections on the heating water side (cont.) Versions Fig. 21 Safety equipment block with safety valve. A low water indicator or minimum pressure limiter must also be installed. Fitting assembly, 3-way with pressure gauge, mini- mum pressure limiter, maximum pressure limiter Fitting assembly, 4-way with pressure gauge, mini- mum pressure limiter, maximum pressure limiter, dummy plugs... -
Page 28: Connecting The Control Unit
Connecting the control unit Connections to the control unit module Boiler control unit installation instructions Note Route 230 V cables and LV leads separately. Please note Hot components can damage electrical cables. Never allow cables/leads to come into contact with hot components. Secure all cables/leads with cable ties. -
Page 29: Connections On The Flue Gas Side
Connections on the flue gas side Flue gas connection and trap Fig. 23 1. Insert the boiler flue connection (accessories) into Do not carry out commissioning until the following the flue outlet as far as it will go. conditions are met: Free passage through the flue gas pipes. -
Page 30: Condensate Drain Pipe
Connections on the flue gas side (cont.) Condensate drain pipe Fig. 24 Route condensate pipe with a fall and below the anti- Connect the neutralising system to the drainage sys- flooding level of the flue gas collector. tem. Condensate drain must be accessible for inspec- Neutralising system installation instructions tion. - Page 31 Gas connection (cont.) Fig. 25 1. Break out the aperture for the gas line at the perfo- 4. Connect the gas supply according to TRGI 2008 ration in the right or left-hand side panel. Use pro- [or local regulations]. tective gloves. AT: Connect the gas supply according to ÖVGW-TR Gas 1996 and the regionally appli- 2.
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Page 32: Commissioning And Adjustment
Gas connection (cont.) 5. Carry out a tightness test. 6. Purge the gas line to the outside. Please note Danger Excessive test pressure will damage the Escaping gas can lead to explosions which burner and gas train. may result in serious injury. Max. - Page 33 Front panel (cont.) 4. Insert 2 screws 6. Affix the product designation label to the front This will protect the front panel against unauthor- panel. ised access. Label showing installation information 5. Pivot the front panel closed and click it into place.
- Page 36 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...