Viessmann Vitocrossal 200 CM2 Series Installation Instructions Manual
Gas condensing boiler with matrix cylinder burner
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Also See for Vitocrossal 200 CM2 Series:
- Technical manual (100 pages) ,
- Service instructions for contractors (72 pages) ,
- Installation instructions manual (52 pages)
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Summary of Contents for Viessmann Vitocrossal 200 CM2 Series
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Page 1: Installation Instructions
VIESMANN Installation instructions for contractors Vitocrossal 200 Type CM2, 400 to 620 kW Gas condensing boiler with MatriX cylinder burner VITOCROSSAL 200 Dispose after installation. 5833527 GB 6/2018... -
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 ................Key to date of manufacture ..............Symbols ....................Intended use ..................Product information ................Siting conditions ........................ Preparing for installation Clearance dimensions ................Components in thermal insulation package ........... Thermal insulation pack 1 ..............10 ■... -
Page 4: Information Disposal Of Packaging
CH: Packaging waste is disposed of by the HVAC contractor. Key to date of manufacture Year Week Fig. 1 Internal Viessmann information Digits 0 and 5 = calendar week 05 = 5th calendar week Digits Digits 1 and 5 = year 2015... -
Page 5: Symbols
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 Pay particular attention. Component must audibly click into place. -
Page 6: Product Information
Product information Vitocrossal 200, type CM2 ■ Permissible operating temperature up to 95 °C. Per- ■ Gas condensing boiler: missible safety temperature up to 110 °C 400 to 620 kW rated heating output with modulat- Delivery: – ■ ing MatriX radiant burner for natural gas E and LL Boiler body on pallet (also for room sealed operation;... -
Page 7: Siting Conditions
Siting conditions Use the installation room exclusively for the installation Ensure the quality of the combustion air drawn in: of the condensing boiler. ■ Combustion air must be free of flammable, explosive gases and vapours. ■ Dust-free, daily mean value < 150 air, Direc- µ... -
Page 8: Preparing For Installation Clearance Dimensions
Adjustable anti-vibration feet (accessories) Burner Anti-vibration boiler supports (accessories) Dimension a: 500 mm Dimension b: 700 mm For dimensions a and b when using Viessmann acces- sories for two-boiler systems, see Flue gas header installation instructions Fig. 4 Anti-vibration boiler supports (accessories) Fig. -
Page 9: Components In Thermal Insulation Package
Clearance dimensions (cont.) Rated heating output Adjustable anti-vibration feet Permissible load 1000 Quantity Anti-vibration boiler supports Permissible load 1500 1750 c Front of boiler Length Quantity c Back of boiler Length Quantity e (unstressed) e (stressed) Components in thermal insulation package The thermal insulation and casing are supplied in 2 packs. -
Page 10: Thermal Insulation Pack 1
Components in thermal insulation package (cont.) Thermal insulation pack 1 Fig. 5 Side panel, left front Side panel Side panel, left rear Side panel, right front Thermal insulation jacket Thermal insulation mat, front Side panel, right rear Front panel, top Side panel, centre Front panel, bottom... -
Page 11: Thermal Insulation Pack 2
Components in thermal insulation package (cont.) Thermal insulation pack 2 qZ qU Fig. 6 Side panel, centre Cover Cable channel, lower section Top panel, left rear Trunking retainer Top panel, right rear Cable channel, upper section Cross brace Mounting bracket fascia Rail, top left Mounting bracket Rail, top right... -
Page 12: Fastenings
Components in thermal insulation package (cont.) Fastenings The following is a list of the components required for For easier identification, the components have been fastening the individual items. assigned circled numbers. Bag of fixing parts from thermal insulation pack 2. Pos. -
Page 13: Installation Sequence Siting And Levelling The Boiler
Siting and levelling the boiler Required parts: Note ■ Adjusting screws are supplied with the boiler. The installation room must be equipped with a suitable condensate drain (maximum 50 mm above floor level) Please note if the boiler is installed at ground level. Damage to the flue gas connection can result in leaks. -
Page 14: Fitting The Thermal Insulation And Casing Sections
Fitting the thermal insulation and casing sections Thermal insulation jacket for boiler body Required parts: Note ■ Thermal insulation jacket from thermal insulation For room sealed operation, attach the ventilation air pack 1 pipe before fitting the thermal insulation panels. ■... -
Page 15: Repositioning The Boiler Door Hinges (If Required)
Fitting the thermal insulation and casing… (cont.) Repositioning the boiler door hinges (if required) Fig. 10 The boiler door can be rehung on the opposite side by moving bolt to the r.h. side. Sealing frame should press centrally onto boiler door gasket when the boiler door is closed. -
Page 16: Top And Bottom Rails And Side Panel Supports
Fitting the thermal insulation and casing… (cont.) Top and bottom rails and side panel supports Parts required from thermal insulation pack 2: Bottom rails ■ ■ Top left rail Screws from bag of fixing parts ■ ■ Top right rail ■... - Page 17 Fitting the thermal insulation and casing… (cont.) Fig. 13 Note The control unit can be fitted on the left or right. Mount the control unit side panel on the right or left accordingly. Secure the side panels to the top rails with two 4.8 screws for each.
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Page 18: Crossbar
Fitting the thermal insulation and casing… (cont.) Crossbar Parts required from thermal insulation pack 2: ■ Cross brace ■ Screws from bag of fixing parts Fig. 14... -
Page 19: Mounting The Burner
Mounting the burner Note All parts required for mounting the burner are con- tained in the burner pack. Fig. 15 Protective foil sleeve Danger Please note When working with high temperature insulating Contamination of the burner gauze assembly materials that contain zirconium or aluminium can lead to malfunctions. -
Page 20: Fitting And Aligning The Front Side Panels
Mounting the burner (cont.) 2. Position the gasket. 7. Remove burner gauze assembly protector 3. Position the burner at the boiler door, guiding the 8. Check the electrode gap (see service instructions) burner gauze assembly carefully through the aper- and the surface of the burner gauze assembly for ture. -
Page 21: Burner Electrical Connection
Fitting and aligning the front side panels (cont.) Fig. 17 3. After hooking in the side panels, align supports so that the panels are flush with each other. Tighten the screws in the supports. Secure the side panels to the supports using one M 6 x 10 screw for each. -
Page 22: System Power Supply
Burner electrical connection (cont.) If using the flue gas header for two-boiler 3. Plug control unit connecting cable , flue gas f-\YBH systems (accessories): temperature sensor lead B and power cable Installation instructions for flue gas header in a on the burner side into the connectors on the fÖ... -
Page 23: Routing Connecting Cables/Leads
Burner electrical connection (cont.) Danger The permanent power supply (power cable with plug Incorrect core assignment can lead to serious ) must be connected in such a way that it can be fÖ injury from electrical current and result in appli- switched off via the mains isolator. -
Page 24: Burner Connections On The Gas Side
Burner electrical connection (cont.) Note on E Route to the flue gas collector. Burner connections on the gas side 2. Connect the gas supply according to TRGI 2008 or TRF 2012 [or local regulations]. Connect the gas supply according to ÖVGW-TR Gas 1996 and the regionally appli- cable building regulations. -
Page 25: Fitting Further Casing Sections
Burner connections on the gas side (cont.) 3. Carry out a tightness test. 4. Purge the gas line. Note Danger Only use suitable and approved leak detection Escaping gas can lead to explosions which agents (EN 14291) and devices for the tightness may result in serious injury. -
Page 26: Top Panels
Fitting further casing sections (cont.) Top panels Parts required from thermal insulation pack 2: Top back left panel ■ ■ Top centre panel Top back right panel ■ ■ Cover panel ■ Screws from bag of fixing parts ■ Top front panel Fig. -
Page 27: Control Unit Installation
Fitting further casing sections (cont.) Fig. 24 Type plate 5. Abut top front panel at the top so that location stud locks into the side panels. Secure with an M 5 screw. Note Align the display of the burner control unit so that it is visible in the viewing window of the front panel. -
Page 28: Connections To The Control Unit Base
Control unit installation (cont.) § Fig. 25 Note 6. Following connection of the cables and leads, The boiler coding card is supplied in a separate pack- secure mounting bracket fascia onto the age. bracket. 5. Fit the control unit, complete with cover and cables/leads. -
Page 29: Connections On The Heating Water Side
Connections on the heating water side Note The Vitocrossal is only suitable for fully pumped hot water heating systems. Never install 4-way mixers, overflow valves or other flow/return bypass devices. Never connect heat consumers to the safety connec- tion. Install all pipe connections free of load and torque stress. -
Page 30: Low Water Indicator (Water Level Limiter)
Making the safety connections (cont.) Low water indicator (water level limiter) Protect the boilers against water shortage in accord- ance with EN 12828. For this, install a minimum pres- sure limiter (accessories) to the fitting assembly. Flash trap According to EN 12828, the flash trap is not required if The safety chain on the boiler side already includes 2 an additional high limit safety cut-out and a safety temperature limiters for restricting the maximum tem-... -
Page 31: Connecting The Neutralising System
Connections on the flue gas side (cont.) Connecting the neutralising system Fig. 28 Installation and operating instructions for neu- 4. Connect drain hose to the condensate drain of tralising system the neutralising system and route to drainage sys- 1. Position neutralising system either behind or next to the boiler. -
Page 32: Specification
Specification Rated heating output For natural gas = 50/30 °C 80 to 400 100 to 500 124 to 620 cond = 80/60 °C 74 to 370 92 to 460 115 to 575 For LPG = 50/30 °C 100 to 400 125 to 500 155 to 620 cond... - 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...
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