Table of Contents
Related Manuals for Viessmann VITOCROSSAL Series
Summary of Contents for Viessmann VITOCROSSAL Series
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Page 1: Installation Instructions
VIESMANN Installation instructions for contractors Vitocrossal Type CIB, 80 to 318 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation VITOCROSSAL Dispose after installation. 5839818 GB 9/2019... - Page 2 Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.
- Page 3 Repair work Please note Repairing components that fulfil a safety function can compromise the safe operation of the system. Replace faulty components only with genuine Viessmann spare parts.
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Page 4: Table Of Contents
Index Information Disposal of packaging ................Symbols ....................Intended use ..................Product information ................System examples ................■ Conversion for other countries ............■ Preparing for installation ........................ Installation sequence Siting and levelling the boiler ..............Fitting the thermal insulation ..............10 Mounting the burner ................ -
Page 5: Intended Use
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 6: Product Information
6 bar (0.6 MPa). modulating MatriX cylinder burner. MatriX cylinder burner with Lambda Pro Control combustion controller System examples Available system examples: See www.viessmann- schemes.com. Conversion for other countries The Vitocrossal may only be delivered to the countries specified on the type plate. - Page 7 Preparing for installation Clearance dimensions 1000 Fig. 1 Delivery and handling The boiler is delivered on a wooden pallet. 1. Remove the bag and place to one side. The following components are delivered in individual The bag contains the following: packages: Boiler flue connection ■...
- Page 8 Preparing for installation (cont.) Handling dimension The boiler is rolled backwards to the installation site on its castors. The handling dimension therefore corre- sponds to the boiler width of 680 mm. Thermal insulation and casing parts Fig. 3 Front panel Thermal insulation jacket Side panel Control unit panel...
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Page 9: 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 level Never lift or move the boiler by the flue gas con- (max. -
Page 10: Fitting The Thermal Insulation
Fitting the thermal insulation Note All required components are included in the thermal insulation box. Fig. 5 Holes for spring hooks for top front thermal insula- tion mat Secure thermal insulation sections with spring hooks. -
Page 11: Mounting The Burner
Mounting the burner Note All parts required for mounting the burner are con- tained in the burner pack. Burners up to 80 kW 1. Insert the burner. Please note Mechanical damage to delicate components will impair the burner function. Exercise great care when inserting the burner into the combustion chamber. -
Page 12: Burners From 120 To 318 Kw
Mounting the burner (cont.) Burners from 120 to 318 kW Note All parts required for mounting the burner are con- tained in the burner pack. M 10 x 30 Fig. 7 Gas connection Ventilation air connection Venturi extension; required accessory for burners from 200 kW for open flue operation (in separate box) 1. -
Page 13: Fitting The Gas Supply Pipe (Accessories)
Fig. 8 Boilers up to 80 kW Routing options for the gas supply pipe If the Viessmann gas supply pipe (accessories) is not Boiler casing pipe knock-out used, select one of the following pipe routing options: On the relevant side or back panel, break out the panel... - Page 14 Fitting the gas supply pipe (accessories) (cont.) Fig. 10 Boilers up to 80 kW Fig. 12 Boilers 120 to 318 kW Fig. 11 Boilers up to 80 kW Fig. 13 Boilers 120 to 318 kW a = Height between top edge of gas pipe and top edge of base rail of the boiler max.
- Page 15 Fitting the gas supply pipe (accessories) (cont.) Note 3. Purge the gas line. We recommend that you use the Viessmann gas sup- ply pipe (accessories). Note The [German] Combustion Order stipulates that ther- 1. Connect the gas supply according to TRGI 2008 mally activated shut-off equipment must be installed in [or local regulations].
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Page 16: Fitting The Set For Room Sealed Operation
Fitting the set for room sealed operation "Accessories for room sealed operation" installa- tion instructions Position of the ventilation air pipe Fig. 14 Boilers up to 80 kW Ventilation air connection Fig. 15 Boilers 120 to 160 kW Ventilation air pipe with adaptor... - Page 17 Fitting the set for room sealed operation (cont.) Fig. 16 Boilers 200 to 318 kW Ventilation air pipe with adaptor...
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Page 18: Fitting The Boiler Flue Connection
Fitting the boiler flue connection Danger Using an incorrect connection piece can lead to flue gas escaping with a dangerous carbon monoxide concentration. Escaping flue gas can cause life threatening carbon monoxide poison- ing. The boiler may only be operated with the original 90°... -
Page 19: Fitting The Trap
Fitting the trap Fill the trap with water, slot it on and tighten. Connect the condensate drain to the neutralising sys- tem (if installed); see page 39. Note The boiler may only be operated with the original trap. Danger Flue gas escaping from the trap can cause potentially fatal carbon monoxide poisoning. -
Page 20: Fitting The Side Panels
Fitting the side panels M 6 x 12 M6 x 12 Fig. 19 1. Insert self-tapping screws (M6 x 12). Hook in the 3. Affix type plate to the right or left side panel. guide rails. Tighten the screws. 2. To facilitate installation, place the bottom of the side panels in the guide rails. -
Page 21: Assembling The Control Unit
Assembling the control unit Fig. 21 Fig. 20 Secure the programming module to the control unit panel with 4 screws (4.8 x 9.5). Insert screws (M6 x 10) only loosely. The screws serve to secure the control unit module to the boiler. Installing the control unit 1. -
Page 22: Connecting The Programming Unit To The Control Unit
Installing the control unit (cont.) Connecting the programming unit to the control unit Open the control unit; to do so undo the control unit The ribbon cable is routed over 2 retainers. panels. For connection, see connection and wiring diagram on page 41. - Page 23 Connecting the internal connecting cables to… (cont.) Cables with moulded strain relief Fig. 26 Note When connecting external switching contacts and on- The wiring diagram is on the underside of the cover site components, observe the insulation requirements panel. of IEC/EN 60335-1. Please note An electrostatic charge may damage electronic assemblies.
- Page 24 Connecting the internal connecting cables to… (cont.) Fig. 28 Extra low voltage (ELV) plug Plug 230 V~ Ionisation electrode Gas train Cable harness: Boiler water and flue gas temper- Ignition unit ature sensor, fan control a-Ö Gas train modulation coil control , for boilers a:Ö...
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Page 25: Fitting The Control Unit To The Boiler
Fitting the control unit to the boiler Please note Hot components can damage electrical cables. Never route electrical cables near hot compo- nents. Observe the maximum permissible tem- peratures for the cables. Fig. 29 1. Hook the pre-assembled control unit into the holes Danger on the side panels. -
Page 26: Connecting The Flue Gas Temperature Sensor
Fitting the control unit to the boiler (cont.) Connecting the flue gas temperature sensor Insert the connector at the prefitted flue gas tempera- ture sensor in the boiler flue connection. Fig. 30 Fitting the back panels Fig. 31... -
Page 27: Boiler Water Temperature Sensor And Water Pressure Switch
Fitting the control unit to the boiler (cont.) Boiler water temperature sensor and water pressure switch Fig. 32 Boiler water temperature sensor (control unit plug Connection (pressure gauge) ½ Connection 1 (safety valve, safety equipment ¼ block) Water pressure switch (control unit plug X9) -
Page 28: Connecting External Cables
Connecting external cables Information on connecting accessories Accessory installation instructions supplied with accessories. 230V~ Fig. 33 Plug 230 V~ DHW circulation pump (accessories) Boiler circuit pump or butterfly valve with return Rated voltage: 230 V~ sÖ spring (only with multi boiler system) Rated current: Max. -
Page 29: Circulation Pump At Plug Sö
Connecting external cables (cont.) Power supply, on output extension SA 169 LV plug fÖ Danger Outside temperature sensor Incorrect core assignment can result in seri- Installation: ous injury and damage to the appliance. North or north-westerly wall, 2 to 2.5 m above ■... -
Page 30: Circulation Pump At Plug Sa
Connecting external cables (cont.) Adjusting the function of the circulation pump Hydraulic connection/connection require- Control unit setting Circulation pump setting ments Coding address/group Single boiler system with: Max. pump speed: Ext. In ■ Ext. In Heating circuit without mixer E6: ... /heating circuit ■... -
Page 31: Pumps With Power Consumption Greater Than 2 A Or Connection For He Pump
Connecting external cables (cont.) Pumps with power consumption greater than 2 A or connection for HE pump For switching the contactor Rated current 4(2) A~ Recommended connecting H05VV-F3G 0.75 mm cable H05RN-F3G 0.75 mm External demand via switching contact Connection options: N PE ■... -
Page 32: External Demand Via 0
Connecting external cables (cont.) Plug EA1 extension Floating contact Floating contact (when connecting, remove jumper EA1 extension between L and 1) Parameters/codes Parameters/codes "4b:1" in the "General"/1 group Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) to 2 in the ■... -
Page 33: Connection Of Accessories
Connecting external cables (cont.) Please note Live contacts lead to short circuits or phase fail- ure. The external connection must be floating and meet the requirements of protection class II. Plug EA1 extension Floating contact Floating contact (when connecting, remove jumper EA1 extension between L and 1) Parameters/codes... -
Page 34: Burner Electrical Connection
Burner electrical connection Route the cables/leads forwards from the control unit to the burner. Burners up to 80 kW a:-] a--] a-Ö a:Ö Fig. 41 LV plug Plug 230 V~ Ionisation electrode A Gas train Fan control Fan and ignition unit a-Ö... -
Page 35: Burners 120/160 Kw
Burner electrical connection (cont.) Burners 120/160 kW a:Ö a--] a-Ö Fig. 42 LV plug Plug 230 V~ Ionisation electrode Gas train A Fan control a-Ö a-Ö Gas train modulation coil control Ignition unit a:Ö Combustion chamber pressure switch A Digital flame amplifier... -
Page 36: Burners 200/240/280/318 Kw
Burner electrical connection (cont.) Burners 200/240/280/318 kW a:Ö a-Ö Fig. 43 LV plug Plug 230 V~ Ionisation electrode Gas train A Fan control a-Ö a-Ö Gas train modulation coil control Ignition unit a:Ö Combustion chamber pressure switch A Digital flame amplifier Electrical connection of the motorised flue gas damper in multi boiler systems Multi boiler system with max. -
Page 37: Inserting The Coding Card
Inserting the coding card Note The coding card must be installed at zero volt. The coding card is supplied in the burner packaging. Fig. 44 Fitting the top panels 4.8 x 9.5 2. Align the side panels parallel to the top panels and tighten the screws. -
Page 38: 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 a heating return to the safety return. Please note Connections subject to mechanical loads can cause appliance damage. -
Page 39: Connecting The Condensate Drain
Connecting the condensate drain Condensate drain Connect the trap with the plastic hose to the drain- The condensate drain must be freely accessible for ■ ■ age system. inspection where it enters the drainage system. ■ Route the condensate drain with a fall and below the ■... -
Page 40: Fitting The Front Panel
Flue gas connection (cont.) Danger Leaking or blocked flue systems or an insuffi- cient supply of combustion air cause life threat- ening poisoning due to carbon monoxide in the flue gas. Ensure the flue system functions correctly. Aper- tures for combustion air supply must not be able to be closed off. -
Page 41: Connection And Wiring Diagram
Connection and wiring diagram Fig. 49 Outside temperature sensor Circulation pump, either: Flow temperature sensor for low loss header ■ Circulation pump for cylinder heating (accessories) External heating circuit pump ■ Cylinder temperature sensor ■ DHW circulation pump sÖ Boiler circuit pump or butterfly valve with return spring... -
Page 42: Specification
Connection and wiring diagram (cont.) Internal H1 extension Main PCB ■ Central fault message Coding card DHW circulation pump ON/OFF switch ■ External heating circuit pump Programming unit ■ ■ Circulation pump for cylinder heating Connection adaptor with Optolink Gas train Connection adaptor Flue gas damper (accessories) LON communication module (accessories) - Page 43 Specification (cont.) Rated heating output range : TF/TR = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 cond : TF/TR = 80/60 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Weight Overall unit weight...
- Page 44 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...