Viessmann Vitocrossal Installation Instructions Manual
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Viessmann Vitocrossal Installation Instructions Manual

Gas condensing boiler with matrix cylinder burner
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VIESMANN
Installation instructions
for contractors
Vitocrossal
Type CIB unit, 80 to 318 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
Fully pre-assembled and wired
VITOCROSSAL
Dispose after installation.
5839853 GB
7/2020

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Summary of Contents for Viessmann Vitocrossal

  • Page 1 VIESMANN Installation instructions for contractors Vitocrossal Type CIB unit, 80 to 318 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation Fully pre-assembled and wired VITOCROSSAL Dispose after installation. 5839853 GB 7/2020...
  • 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.

  • Page 4: Table Of Contents

    Index Information Disposal of packaging ................Symbols ....................Intended use ..................Product information Product information ................System examples .................. Conversion for other countries ............... Preparing for installation ........................ Installation sequence Siting and levelling the boiler ..............Removing the front panel ............... Fitting the gas supply pipe (accessories) ..........

  • Page 5: Information 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 Product Information

    Product information Vitocrossal, type CIB, 80 to 318 kW with permissible Gas condensing boiler for natural gas E, L and LL, with operating pressure 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-...

  • Page 7: 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 protective foil, edge protection and the To facilitate handling, rigid castors are fitted at the back top board. and a swivel castor at the front of the boiler.
  • Page 8 Preparing for installation (cont.) The boiler is equipped with further transport aids Fig. 3 Alternative transport aids Reducing the handling dimensions 4 holes to slide poles (to be provided by the cus- The casing and certain other components can be tomer) through as a transport aid removed to reduce the handling dimensions.

  • Page 9: Installation Sequence Siting And Levelling The Boiler

    Siting and levelling the boiler Note Extend the adjustable feet until the castors are free of A suitable condensate drain must be available in the load. installation room if the boiler is installed at ground level Level the boiler with its adjustable feet. (max.

  • Page 10: Fitting The Gas Supply Pipe (Accessories)

    Ensure all gas connections are kept free of load and torque stress. Routing options for the gas supply pipe If the Viessmann gas supply pipe (accessories) is not Danger used, select one of the following pipe routing options: Sharp edged metal panels can cause cuts.
  • Page 11 Fitting the gas supply pipe (accessories) (cont.) Fig. 8 Boilers up to 80 kW Fig. 10 Boilers from 120 kW Fig. 9 Boilers up to 80 kW Fig. 11 Boilers from 120 kW a = Height between top edge of gas pipe and top edge of base rail of the boiler max.

  • Page 12: 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 13: 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 pipes for room sealed operation To provide a better overview, the boiler is shown in the drawings without its casing. Fig. 13 Boilers 120 to 160 kW Ventilation air pipe with adaptor Fig.

  • Page 14: Fitting The Boiler Flue Connection

    Fitting the set for room sealed operation (cont.) Fig. 14 Boilers from 200 kW Ventilation air pipe with adaptor Fitting the boiler flue connection Danger Using an incorrect connection piece can lead to flue gas escaping with a dangerous carbon monoxide concentration.
  • Page 15 Fitting the boiler flue connection (cont.) Fig. 15 1. Hook in the retaining bracket. 3. Secure with two M 8 screws; torque 18 Nm. 2. Push the boiler flue connection onto the flue outlet as far as it will go. Note Gaskets have already been inserted in the...

  • Page 16: Fitting The Trap And Flue Gas Temperature Sensor

    Fitting the trap and flue gas temperature sensor 1. Connect the pre-routed lead to the flue gas tem- perature sensor in the boiler flue connection. 2. Fill the trap with water, slot it on and tighten. Fig. 16 Condensate drain ■...

  • Page 17: Fitting The Front Panel

    Connecting the neutralising system (accessories) (cont.) 1. Position neutralising system behind the boiler. 2. Connect drain hose to the trap. 3. Connect neutralising system drain hose to the drainage system. Fig. 17 Drain hose from trap to neutralising system, external of connection: 17 mm Drain hose from neutralising system to drainage system...

  • Page 18: Boiler Electrical Connection

    Boiler electrical connection Opening the control unit Fig. 19...

  • Page 19: Routing Cables And Leads

    Boiler electrical connection (cont.) Routing cables and leads Danger Incorrectly executed electrical installations can result in injuries from electrical current and dam- age to the appliance. ■ Route extra low voltage (ELV) leads ∼ > 42 V/230 V cables separately. Strip as little of the insulation as possible, ■...

  • Page 20: External Cables

    Boiler electrical connection (cont.) Cables with moulded strain relief Fig. 22 External cables Information on connecting accessories Accessory installation instructions supplied with accessories.
  • Page 21 Boiler electrical connection (cont.) 230V~ Fig. 23 Plug 230 V~ Power supply, on output extension SA 169 fÖ Boiler circuit pump or butterfly valve with return Danger sÖ spring (only with multi boiler system) Incorrect core assignment can result in seri- Rated voltage: 230 V~ ous injury and damage to the appliance.

  • Page 22: Circulation Pump At Plug Sö

    Detailed connection diagrams side the wet area must not be connected to the Service instructions for the "Vitocrossal, type power supply at the control unit. CIB" If the boiler is not sited in a wet room, the power supply for accessories can be connected at the control unit.

  • Page 23: Circulation Pump At Plug Sa

    Boiler electrical connection (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 24: Pumps With Power Consumption Greater Than 2 A Or Connection For He Pump

    Boiler electrical connection (cont.) Pumps with power consumption greater than 2 A or connection for HE pump N PE External ON/OFF Fig. 27 Pump (on site) To the control unit Contactor (on site) Separate power supply (observe manufacturer's instructions) Pumps 400 V~ For switching the contactor L1 L2 L3 N PE Rated current...

  • Page 25: External Demand Via 0 - 10 V Input

    Boiler electrical connection (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 26: Connection Of Accessories

    Boiler electrical connection (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 27: Electrical Connection Of The Motorised Flue Gas Damper In Multi Boiler Systems

    Electrical connection of the motorised flue gas damper in multi boiler systems Multi boiler system with max. 2 boilers Note If there is a separate flue system for each boiler, no Required accessories for a common flue system flue gas damper is required. In the case of common flue systems or a flue gas ■...

  • Page 28: 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 29: Flue Gas Connection

    Connect the flue outlet to the flue with the shortest Flue gas connection: 200 mm possible run, maintaining a slight rise (min. 3°). Avoid sharp kinks. Commissioning and adjustment Service instructions for the "Vitocrossal, type CIB" and boiler control unit...

  • Page 30: Appendix Connection And Wiring Diagram

    Connection and wiring diagram Fig. 33 Outside temperature sensor Circulation pump, either: Circulation pump for cylinder heating Flow temperature sensor ■ Cylinder temperature sensor External heating circuit pump ■ Setting for heating circuit pump, boiler circuit ■ DHW circulation pump sÖ...

  • Page 31: 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 Switching mode power supply in main PCB DHW circulation pump Coding card ■...
  • Page 32 Specification (cont.) Rated heating output range = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 cond = 80/60 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Foundation dimensions Length...

  • Page 33: Matrix Cylinder Burner Specification

    Specification (cont.) Rated heating output range = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 cond = 80/60 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Product parameters accord- ing to EnEV...
  • 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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