Viessmann VITOCROSSAL Installation Instructions Manual
80 to 318 kw. gas condensing boiler with matrix cylinder burner. open flue and room sealed operation
Hide thumbs
Also See for VITOCROSSAL:
- Service instructions manual (112 pages) ,
- Installation instructions for contractors (40 pages) ,
- Installation instructions manual (40 pages)
Table of Contents
Related Manuals for Viessmann VITOCROSSAL
Summary of Contents for Viessmann VITOCROSSAL
- Page 1 VIESMANN Installation instructions for contractors Vitocrossal Type CI, 80 to 318 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation VITOCROSSAL Dispose after installation. 5814780 GB 2/2018...
- Page 2 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 ............■ Preparing for installation ........................ Installation sequence Siting and levelling the boiler ..............Fitting the thermal insulation ..............10 Mounting the burner ................11 Fitting the gas supply pipe (accessories) .......... -
Page 4: Information Disposal Of Packaging
Disposal of packaging Disposal of packaging DE: Use the disposal system organised by Viessmann. Please dispose of packaging waste in line with statu- AT: Use the ARA statutory disposal system (Altstoff tory regulations. Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor. -
Page 5: Product Information
Intended use also includes the adherence to mainte- nance and inspection intervals. Product information Vitocrossal, type CI, 80 to 318 kW with permissible Gas condensing boiler for natural gas E, L and LL, with operating pressure 6 bar (0.6 MPa). -
Page 6: Preparing For Installation
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 7 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 mat, bottom back Side panel Thermal insulation mat, centre back...
- Page 8 Preparing for installation (cont.) Back panel, top Back panel, bottom...
-
Page 9: 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 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, upper thermal insulation 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. Please note Mechanical damage to delicate components will impair the burner function. Exercise great care when inserting the burner into the combustion chamber. The burner gauze assembly, electrodes and insulation block must not be damaged. - Page 12 Mounting the burner (cont.) M10x30 Fig. 7 Burners 120 - 318 kW Gas connection Ventilation air connection Venturi extension for burners from 200 kW for open flue operation (in separate box) Please note Mechanical damage to delicate components will impair the burner function. Exercise great care when inserting the burner into the combustion chamber.
-
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.) a = Height between top edge of gas pipe and top edge of base rail of the boiler max. 60 mm. Fig. 12 Boilers 120 to 318 kW Fig. 10 Boilers up to 80 kW Fig.
-
Page 15: Burner Connections On The Gas Side
Burner connections on the gas side 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]. -
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.) "Accessories for room sealed operation" installa- tion instructions Fig. 16 Boilers 200 to 318 kW Ventilation air pipe with adaptor...
-
Page 18: Fitting The Boiler Flue Connection
Fitting the boiler flue connection Danger Using an incorrect flue connection can lead to dangerous carbon monoxide concentrations in the flue gas. Escaping flue gas can cause life threatening carbon monoxide poisoning. 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 37. 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 And Back Panels
Fitting the side and back panels Fig. 19 1. Insert M 6 x 10 screws. Hook the rails into place. 4. Hook the top back panel into the side panels. Tighten the screws. 5. Click the edge protectors into place. 2. -
Page 21: Assembling The Control Unit
Assembling the control unit Fig. 21 Fig. 20 Secure the programming unit to the control unit panel with 4 screws 4.8 x 9.5. Insert screws M 6 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 40. - Page 23 Connecting the internal connecting cables to… (cont.) Cables with moulded strain relief Fig. 26 Note Danger The wiring diagram is on the underside of the cover Incorrectly executed electrical installations can panel. result in injuries from electrical current and dam- age to the appliance.
-
Page 24: Fitting The Control Unit To The Boiler
Connecting the internal connecting cables to… (cont.) Fig. 28 LV plug Plug 230 V~ Ionisation electrode Gas train X9 Combustion chamber pressure limiter, gas train Ignition unit modulation coil control , for boilers up to 80 kW a:Ö a-Ö additionally a:Ö... - Page 25 Fitting the control unit to the boiler (cont.) Fig. 29 1. Hook the pre-assembled control unit into the holes Danger on the side panels. Incorrectly executed electrical installations can result in injuries from electrical current and dam- 2. Tighten the screws. age to the appliance.
-
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 Boiler water temperature sensor Insert the connector at the prefitted boiler water tem- perature sensor in the boiler floor. -
Page 27: Connecting External Cables
Connecting external cables Information on connecting accessories Accessory installation instructions supplied with accessories. 230V~ 0-10 V Fig. 32 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 28: 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 ■... - Page 29 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 30 Connecting external cables (cont.) Pumps with power consumption greater than 2 A For switching the contactor or connection for HE pump 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: EA1 extension (accessory, see separate installation ■...
-
Page 31: External Demand Via 0 - 10 V Input
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 32: 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 33: Burner Electrical Connection
Burner electrical connection Route the cables/leads forwards from the control unit to the burner. Burners 80 kW a:-] a--] a-Ö a:Ö Fig. 40 LV plug Plug 230 V~ Ionisation electrode A Gas train Fan control Fan and ignition unit a-Ö a-Ö... -
Page 34: Burners 120/160 Kw
Burner electrical connection (cont.) Burners 120/160 kW a:Ö a--] a-Ö Fig. 41 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 limiter A Digital flame amplifier... -
Page 35: Burners 200/240/280/318 Kw
Burner electrical connection (cont.) Burners 200/240/280/318 kW a:Ö 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 limiter A Digital flame amplifier... -
Page 36: Inserting The Coding Card, Fitting The Top Panels
Fig. 43 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. -
Page 37: Making The Safety Connections
Connections on the heating water side (cont.) Making the safety connections Safety equipment block installation instructions 2. Check the connections on the heating water side for leaks. 1. Install the safety lines. Permiss. operating pres- 6 bar (0.6 MPa) sure Min. -
Page 38: 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 39: Fitting The Front Panel
5. Push the front panel closed. 2. Insert the location stud into the front panel and secure. 3. Position the front panel in the lower rim and flip it shut tightly. Commissioning and adjustment "Vitocrossal, type CI" service instructions and boiler control unit operating instructions... -
Page 40: Appendix Connection And Wiring Diagram
Connection and wiring diagram Fig. 48 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 Boiler circuit pump or butterfly valve with return Code 39 sÖ... -
Page 41: Specification
Connection and wiring diagram (cont.) Relay output, either: Fan motor a¢Ö ■ Central fault message 0-10 V Circulation pump for cylinder heating Main PCB ■ ■ External heating circuit pump Coding card DHW circulation pump ON/OFF switch ■ Code 53 Programming unit Gas train Connection adaptor with Optolink... - Page 42 Specification (cont.) Rated heating output range TF/TR = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 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...