Viessmann Vitocrossal 100 Installation Instructions For Contractors
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Viessmann Vitocrossal 100 Installation Instructions For Contractors

Gas condensing boiler with matrix cylinder burner open flue and room sealed operation fully pre-assembled and wired
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VIESMANN
Installation instructions
for contractors
Vitocrossal 100
Type CI1 unit, 80 to 318 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
Fully pre-assembled and wired
VITOCROSSAL 100
Dispose after installation.
5795 919 GB
3/2017

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Summary of Contents for Viessmann Vitocrossal 100

  • Page 1 VIESMANN Installation instructions for contractors Vitocrossal 100 Type CI1 unit, 80 to 318 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation Fully pre-assembled and wired VITOCROSSAL 100 Dispose after installation. 5795 919 GB 3/2017...
  • 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 Product information ................Conversion for other countries ............... Preparing for installation ........................ Installation sequence Siting and levelling the boiler ..............Removing the front panel ............... Fitting the gas supply pipe (accessories) ..........10 Routing options for the gas supply pipe ..........

  • Page 4: Information Disposal Of Packaging

    Please dispose of packaging waste in line with statu- tory regulations. DE: Use the disposal system organised by Viessmann. AT: Use the ARA statutory disposal system (Altstoff Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor.
  • Page 5 Intended use (cont.) Every other use will be deemed to be inappropriate. Any 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.

  • Page 6: Product Information Product Information

    Product information Vitocrossal 100, type CI1, 80 to 318 kW with permissi- ble operating pressure 6 bar (0.6 MPa). Gas condensing boiler for natural gas E, L and LL, with modulating MatriX cylinder burner. MatriX cylinder burner with Lambda Pro Control combustion controller...

  • 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 wooden crate To facilitate handling, rigid castors are fitted at the back and a swivel castor at the front of the boiler. Leave the 2.
  • Page 8 Preparing for installation (cont.) The boiler is equipped with further transport aids Fig. 3 Alternative transport aids 4 holes to slide poles through for lifting. Remove front panel; see page 9. Crane lug Remove top panels; see page 19. Option for pallet truck insertion underneath Remove front panel;...

  • 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. 10 Boilers 120 to 318 kW Fig. 8 Boilers up to 80 kW Fig. 11 Boilers 120 to 318 kW Fig. 9 Boilers up to 80 kW Gas supply pipe and room sealed operation When routing the gas supply pipe for room sealed operation take into account the position of the air hose.

  • 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 set for room sealed operation (cont.) "Accessories for room sealed operation" installa- tion instructions Fig. 14 Boilers 200 to 318 kW Ventilation air pipe with adaptor...

  • Page 15: 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 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: Connecting The Neutralising System (Accessories)

    Connecting the neutralising system (accessories) "Neutralising system" installation and service instructions 1. Remove the bottom front cover. 2. Place neutralising system under the boiler from the front. Use a long drain hose , so that the neutralising system can be pulled out forwards. 3.

  • Page 18: Fitting The Front Panel

    Fitting the front panel Fig. 19 2. Secure the front panel with the screws.

  • Page 19: Boiler Electrical Connection

    Boiler electrical connection Opening the control unit Fig. 20...

  • Page 20: Routing Cables And Leads

    Boiler electrical connection (cont.) Routing cables and leads Note Secure cables/leads to the boiler with cable ties. Use the existing brackets in the top rail to do so. Danger Incorrectly executed electrical installations can result in injuries from electrical current and dam- age to the appliance.
  • Page 21 Boiler electrical connection (cont.) Cables with moulded strain relief Fig. 23...

  • Page 22: External Cables

    Boiler electrical connection (cont.) External cables Information on connecting accessories Accessory installation instructions supplied with accessories. 230V~ 0-10 V Fig. 24...
  • Page 23 Detailed connection diagrams ■ Install an isolator in the power cable to provide "Vitocrossal 100, type CI1" service instructions omnipolar separation from the mains for all active conductors, corresponding to overvoltage category III (3 mm) for full isolation. The isolator must be fitted in the permanent electrical installa- tion, in line with installation requirements.

  • Page 24: Circulation Pump At Plug Sö

    Boiler electrical connection (cont.) Circulation pump at plug sÖ If variable speed control is possible, insert 0 - 10 V plug-in connection at X4. Rated current 2(1) A~ Rated voltage 230 V ~ sÖ 0 - 10 V Fig. 25 High efficiency circulation pump, speed-controlled via 0 - 10 V control voltage Adjusting the function of the circulation pump...

  • Page 25: Circulation Pump At Plug Sa

    Boiler electrical connection (cont.) Circulation pump at plug Rated current 2(1) A~ Rated voltage 230 V ~ Set function of connected component in coding address "39" Function Code DHW circulation pump 39:0 Heating circuit pump for heating circuit 39:1 without mixer A1 Circulation pump for cylinder heating 39:2 Fig.

  • Page 26: Pumps 400 V

    Boiler electrical connection (cont.) Pumps 400 V~ For switching the contactor L1 L2 L3 N PE Rated current 4(2) A~ Recommended connecting H05VV-F3G 0.75 mm cable H05RN-F3G 0.75 mm Fig. 29 Pump To the control unit Contactor External demand via switching contact Connection options: Please note EA1 extension (accessory, see separate installation...

  • Page 27: External Demand Via 0 - 10 V Input

    Boiler electrical connection (cont.) Plug EA1 extension Floating contact Floating contact (when connected, remove jumper EA1 extension between L and 1) Codes Codes "4b:1" in group "General"/1 Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) to 2 in ■ ■ Effect of the function on the relevant heating circuit group "General"/1 ■...

  • Page 28: 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 connected, remove jumper EA1 extension between L and 1) Codes...

  • Page 29: Fitting The Top Panels

    Fitting the top panels 4.8 x 9.5 3. Align the top panel with the boiler. 4. If necessary, do not fit the back top panel until after the heating water connections have been installed. Fig. 32...

  • Page 30: 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 load can cause appliance damage.

  • Page 31: 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 "Vitocrossal 100, type CI1" and boiler control unit service instructions...

  • Page 32: Appendix Connection And Wiring Diagram

    Connection and wiring diagram Fig. 34 Outside temperature sensor Circulation pump, either: Flow temperature sensor ■ Circulation pump for cylinder heating Cylinder temperature sensor ■ External heating circuit pump Setting for heating circuit pump, boiler circuit ■ DHW circulation pump sÖ...

  • Page 33: 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 34 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 Foundation dimensions Length...
  • Page 35 Specification (cont.) Rated heating out- put range TF/TR = 50/30 16 - 75 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 TF/TR = 80/60 15 - 69 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Rated heat input...
  • Page 36 Specification (cont.) Rated heating out- put range TF/TR = 50/30 16 - 75 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 TF/TR = 80/60 15 - 69 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Connections...

  • Page 37: Matrix Cylinder Burner Specification

    Specification (cont.) MatriX cylinder burner specification Rated boiler heating output 50/30 °C Twin boiler Burner heating output, lower/ kW 15.1/75. 30.2/11 30.2/15 45.3/18 45.3/22 60/264. 60/300 upper output Burner type 75/80k 120/160 120/160 200/240 200/240 280/318 280/318 Product ID See boiler Voltage Frequency Power consumption...
  • Page 40 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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