Viessmann CRU Installation Instructions For Contractors Download Page 1

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Installation instructions

for contractors

VIESMANN

Vitocrossal
Type CRU

, 800 to 1000 kW

Gas condensing boiler

VITOCROSSAL

5816716 GB

1/2018

Dispose after installation.

Summary of Contents for CRU

Page 1: ...Installation instructions for contractors VIESMANN Vitocrossal Type CRU 800 to 1000 kW Gas condensing boiler VITOCROSSAL 5816716 GB 1 2018 Dispose after installation ...

Page 2: ...gulations 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 a ÖNORM EN ÖVGW G K directives ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VK...

Page 3: ...ic 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...

Page 4: ...tic 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 ser...

Page 5: ... 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 5816716 ...

Page 6: ...to 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 ...

Page 7: ...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 5816716 ...

Page 8: ... 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 ...

Page 9: ...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 5816716 ...

Page 10: ... 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 ...

Page 11: ...ide 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 combusti...

Page 12: ...justable 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 5816716 ...

Page 13: ... 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...

Page 14: ...ions Fitting the thermal insulation 12x A 1 2 3 5 4 Fig 10 A Black 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 5816716 ...

Page 15: ...e 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 5816716 ...

Page 16: ...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 5816716 ...

Page 17: ... Rail top short C Rail bottom long D Rail 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 5816716 ...

Page 18: ...th 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 5816716 ...

Page 19: ... 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 5816716 ...

Page 20: ...able 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 ...

Page 21: ...21 Connecting the burner cables 152 95 53 3A 3B 15A 15B 100 Fig 17 Burner electrical connection cont 5816716 ...

Page 22: ...22 1 1 2 3 4 4 Fig 18 Note Use self tapping screws 7 4 8 Fitting the side panels 5816716 ...

Page 23: ...23 3 1 2 Fig 19 Note Use self tapping screws 7 4 8 Attaching the control unit panel to the front top panel 5816716 ...

Page 24: ...24 2 1 Fig 20 2 Only screw in the ball studs Note Joints and gas struts are included in thermal insulation pack 2 Attaching the front top panel with programming unit 5816716 ...

Page 25: ... Fig 21 4 Screw in the ball studs 5 Push the gas struts with joint capsule onto the ball studs taking care not to remove any spring clips in the process Attaching the front top panel with programming cont 5816716 ...

Page 26: ...26 C B A C BA Fig 22 A LAN cable B Data cable to the control unit C 230 V cable Attaching the front top panel with programming cont 5816716 ...

Page 27: ...27 2 1 1 3 Fig 23 1 Edge protection is included in thermal insulation pack 2 Attaching the control unit to the upper back panels 5816716 ...

Page 28: ...onnect the flue gas temperature sensor 5 Insert the plug for the flue gas dampers through the hole from the rear Turn plug by 90 6 Insert the LAN socket from the rear Fasten with 2 screws 7 3 5 Attaching the back panels 5816716 ...

Page 29: ...cable neatly behind the back panel Please note Hot components can damage electrical cables Never route cables near hot components 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 Connecting the control module 5816716 ...

Page 30: ...F Ignition unit G Fuel valve BV1 H Fan motor with PWM switching and feedback K Display and programming unit L Air pressure switch 1 M Gas pressure switch GDW1 N Air pressure switch 2 O Flue gas temperature sensor 1 P Flue gas temperature sensor 2 R Boiler water temperature sensor 1 S Boiler water temperature sensor 2 T Terminal box U Gas pressure switch GDW2 V Fuel valve BV2 Connecting the control...

Page 31: ...ection diagram for the power supply box PE PE PE L1 L1 L2 L3 4 N N N 40 156 100A A1 A2 14 13 5L3 6T3 1L1 2T1 3L2 4T2 L N N L 100 L1 N 4 L2 L3 Base I Grid 400 V 3 100A Fig 27 Connecting the control module cont 5816716 ...

Page 32: ...trap onto the condensate drain of the flue gas collector and tighten by hand 2 Undo the bottom section of the trap and fill it with water 3 Refit the bottom section of the trap Danger Escaping flue gas poses a risk to health If the trap is not full flue gas can escape Fill the trap with water Fitting the top panels and control unit cover 5816716 ...

Page 33: ...on instructions 1 The boiler flue connection accessory is essential for making the flue connection 2 Push collar D onto the flue gas connection of the flue gas collector 3 Fit boiler flue connection C 4 Tighten hose clip A on the collar 5 Connect the flue outlet with the shortest possible run to the chimney maintaining a slight incline Avoid sharp kinks Note A sealable test port B is fitted to the...

Page 34: ...34 3 4x 2 4 2x 5 1 4x Fig 32 Fitting the front side panels 5816716 ...

Page 35: ...te The German Combustion Order stipulates that thermally activated shut off equipment must be installed in the gas line If the gas line is contami nated e g old pipes with corrosion products we recommend installing a gas filter in the supply line Max permiss gas supply pressure 100 mbar 10 kPa 4 Carry out a tightness test Please note Excessive test pressure will damage the burner and gas train Max...

Page 36: ...t the bottom Pivot up the front panel ensuring that the holes at the top are still accessible 3 Insert 2 screws using a Phillips screwdriver This will protect the front panel against unauthorised access 4 Pivot the front panel closed and click it into place 5 Affix the type plate Fitting the front panel 5816716 ...

Page 37: ...37 Vitocrossal type CRU service instructions Commissioning 5816716 ...

Page 38: ...38 5816716 ...

Page 39: ...39 5816716 ...

Page 40: ... Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5816716 Subject to technical modifications ...

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