VIESMANN. Installation instructions VITOCROSSAL 200. for contractors. Vitocrossal 200 Type CM2 Gas fired condensing boiler with MatriX radiant burner

Transcription

1 Installation instructions for contractors VIESMANN Vitocrossal 200 Type CM2 Gas fired condensing boiler with MatriX radiant burner VITOCROSSAL 200 2/2007 Dispose after installation.

2 Safety instructions 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. Details identified by the word "" contain additional information. Regulations Observe the following when working on this system & all legal instructions regarding the prevention of accidents, & all legal instructions regarding environmental protection, & thecodeofpracticeofrelevant trade associations, & all current safety regulations as defined by DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable standards. Target group These instructions are exclusively designed for qualified personnel. & Work on gas appliances must only be carried out by a qualified gas fitter. & Work on electrical equipment must only be carried out by a qualified electrician. Workingonthesystem & Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a mains isolator. & Safeguard the system against unauthorised reconnection. & When using gas as fuel, also close the main gas shut off valve and safeguard against unauthorised reopening. 2

3 Index Preparing for installation... 4 Installation sequence Boiler positioning and levelling... 5 Fitting the thermal insulation... 6 & Thermal insulation mats... 6 & Side panels... 7 & Front panels... 8 & Thermal insulation mat at the back and back panels... 9 Control unit installation Connection on the heating water side Making the safety connections Electrical connections and top panel installation & Cables & Connections to the control unit base & Top panels and covers Connection on the flue gas side & Flue gas connection and siphon & Condensate drain Burner installation Burner connection on the gas supply side Electrical burner connection Fitting the burner hood Commissioning and adjustment

4 Preparing for installation Clearance dimensions A Boiler Dimensions in brackets are minimum clearances. Dim. a: 500 mm Dim. b: 400 mm B Burner C Adjustable anti-vibration boiler supports (accessories) When using Viessmann accessories for two-boiler systems, dimensions a andbapply. Installation instructions flue gas header and hydraulic system connection 4

5 Boiler positioning and levelling! Please note Damageontheflueoutletcan lead to flue gas escaping. Never lift or move the boiler at theflueoutlet. A suitable condensate drain (maximum 50 mm above floor level) must be available inside the installation room, if the boiler is mounted at ground level. 1. Insert adjustable feet A from above into the bottom rails. The adjustable feet are supplied in the accessories pack. 2. Level the boiler. Special foundations are not required. We recommend the installation of the boiler on adjustable antivibration supports (accessories). Insert these from below into the bottom rails. 5

6 Fitting the thermal insulation All required components are included in the thermal insulation carton. Thermal insulation mats In case of balanced flue operation, attach the ventilation pipe before fitting the thermal insulation panels. Accessory installation instructions for balanced flue operation. 6

7 Fitting the thermal insulation (cont.) Side panels Secure the side panels to the upper fixing rails. 7

8 Fitting the thermal insulation (cont.) Front panels Fully insert the screws into the front panel top after fitting the boiler temperature sensor and the sensors (see page 13). Prepare an aperture for the ventilation pipe in the front panel when operating the boiler in balanced flue mode. Accessory installation instructions for balanced flue operation. 8

9 Fitting the thermal insulation (cont.) Thermal insulation mat at the back and back panels Align the side panels, if required, to match the front and back panels. For this, undo the oval head screws in the top fixing rails. 9

10 Control unit installation! Please note Damaged capillaries result in incorrect sensor functions. Never kink the capillary tubes. Screws for securing the control unit are included in the carton of the control unit facia. Connection on the heating water side The Vitocrossal is only suitable for pumped hot water heating systems. Never install four-way mixers, overflow valves or other flow/return bypass devices. Never connect heat consumers to a safety connection. Install all pipe connections free of load and torque stresses. 10

11 Connection on the heating water side (cont.) A Female connection for control equipment R ½" (e.g. minimum pressure switch) E Drain and diaphragm expansion vessel connection R 1" KOA Condensate drain R ½" KR KV SA Boiler return 87to142kW: PN6DN50 186to311kW: PN6DN65 Boiler flow 87to142kW: PN6DN50 186to311kW: PN6DN65 Safety connection (safety valve and air vent valve) G 1¼" 1. Flush the heating system thoroughly. 2. Connect the heating circuits. 11

12 Making the safety connections 1. Make the safety connection. 2. Check the primary connections for possible leaks. Permiss. op. pressure: 4 bar Test pressure: 5.2 bar Low water indicator (water level limiter) Protect the boilers against low water in accordance with EN For this purpose, the minimum pressure switch (available as accessory) can be used. Safety valve Equip boilers with a safety valve that is type-tested according to TRD 721 [or local regulations]. This valve must be marked in accordance with the relevant system. Install all pipe connections free of load and torque stresses.! Please note Unsuitable water qualities can result in boiler body damage. Only fill the boiler with water that complies with the "Water quality requirements" (see service instructions). Electrical connections and top panel installation Cables Boiler water temperature sensor and power supply cable plug fö are included in the control unit package. Boiler cables fa and lö are included in the thermal insulation pack.! Please note Damaged capillaries result in incorrect sensor functions. Never kink the capillary tubes. Route the 230 V cables and LV cables separately. 12

13 Electrical connections and top panel installation (cont.) Lift the top of the front panel, and insert the sensor and the boiler water temperature sensor as far as possible into the sensor well. A Sensor B Boiler water temperature sensor! Please note Never allow cables/leads to come into contact with hot components. Secure all cables/leads with cable ties. C Burner cable D Connecting cables Connections to the control unit base Installation instructions, boiler control unit 13

14 Electrical connections and top panel installation (cont.) Top panels and covers A Type plate (optionally on the l.h. or r.h. side) 14

15 Connection on the flue gas side Flue gas connection and siphon 1. Insert the boiler flue connection (accessories) until it bottoms inside the flue gas connector. Connect the flue outlet via the shortest possible run to the chimney stack, maintaining a slight incline (min. 3 ). Avoid sharp bends. 2. Connect the flue system. Flue outlet system size: 87 to 142 kw: mm 186to311kW: mm Flue gas system installation instructions Make all connections free of load and torque stresses. 3. Fillthesiphonwithwaterandfitit to the boiler. 15

16 Connection on the flue gas side (cont.) Condensate drain Route the condensate drain with a fall below the anti-flooding level of the flue gas header. The condensate drain A must be able to be inspected. Connection (external): 719 mm Neutralising system (if installed) Locate the neutralising system behind the boiler and connect it with the condensate drain. Connect the neutralising system to the sewer. Installation instructions; neutralising system Burner installation All parts required for mounting the burner are contained in the burner pack. Thehingebracketisfittedtothel.h. side of the boiler, but may also be fitted to the r.h. side. 16

17 Burner installation (cont.) Tighten the boiler door screws diagonally, with a torque of approx. 18 Nm. 17

18 Burner connection on the gas supply side 1. Connect the mains gas according to TRGI 1986/1996 [or local regulations]. Accordingtothe[German]Combustion Order, a thermal shut-off facility must be installed into the gas supply line. The installation of a gas filter into the supply line is recommended, if the gas line has been contaminated (e.g. old pipes with corrosion products). Gas supply pressure: 20 mbar Max. permissible gas supply pressure: 50 mbar Gas connection: 87 to 186 kw: R 1" 246 and 311 kw: R 1¼" 2. Carry out a soundness test.! Please note Excessive test pressure may damage the burner and the gas valve. Maximum test pressure 150 mbar. If a higher pressure is required for soundness tests, separate the boiler and the gas train from the gas supply pipe (undo the compression fitting). 3. Vent the gas supply pipe. Danger Escaping gas can lead to explosions which may lead to serious injury. The gas pipe should not be vented through the boiler combustion chamber. 18

19 Electrical burner connection 1. Check that the connections "L 1" and "N" are made correctly at the power supply of the control unit. Control unit installation instructions Danger Incorrect core terminations can cause severe injuries and damage to the equipment. Cores"L1"and"N"must never be interchanged. L1: brown N: blue PE: green/yellow 2. Route the burner cables on the hinge side of the door downwards behind the r.h. or l.h. cover. 3. Push burner plugs fa and lö onto the MatriX burner. 4.! Please note Never allow cables/leads to come into contact with hot components. Secure the burner cables at the top front panel and at the r.h. or l.h. side of the cover using cable ties. For this, use holes A in the panel returns. When using the stainless steel flue gas header for two-boiler systems (accessories): Installation instructions, flue gas header (accessories) for two-boiler systems. 19

20 Fitting the burner hood 20

21 Fitting the burner hood (cont.) In balanced flue mode, open out aperture A for the ventilation air hose withasaw. Commissioning and adjustment Service instructions; boiler and boiler control unit Adjust the burner gas throughput to the rated boiler output. 21

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24 Printed on environmentally friendly, chlorine-free bleached paper Viessmann Werke GmbH&Co KG D Allendorf Telephone: Fax: Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: Fax: Subject to technical modifications. 24