Viessmann Vitocrossal 100 User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal 100
Type CI1, 80 to 318 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
VITOCROSSAL 100
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Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations 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
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
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1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
■Conversion for other countries ........................................................... 5
2. Preparing for installation ................................................................................................................ 6
3. Installation sequence Siting and levelling the boiler ................................................................. 9
Fitting the thermal insulation .................................................................. 10
Mounting the burner ............................................................................... 11
Fitting the gas supply pipe (accessories) ............................................... 13
■Routing options for the gas supply pipe ............................................. 13
Burner connections on the gas side ...................................................... 15
Fitting the set for room sealed operation .............................................. 16
■Position of the ventilation air pipe ....................................................... 16
Fitting the boiler flue connection ............................................................ 18
Fitting the trap ........................................................................................ 19
Fitting the side and back panels ............................................................ 20
Assembling the control unit .................................................................... 21
Installing the control unit ........................................................................ 21
■Connecting the programming unit to the control unit .......................... 22
Connecting the internal connecting cables to the control unit ............... 22
■Applying strain relief ........................................................................... 22
Fitting the control unit to the boiler ......................................................... 24
Connecting the flue gas temperature sensor ......................................... 26
Connecting external cables ................................................................... 27
■Circulation pump at plug sÖ ................................................................ 28
■External demand via 0 – 10 V input .................................................... 31
■External blocking via switching contact .............................................. 31
■Connection of accessories ................................................................. 32
Burner electrical connection .................................................................. 33
■Burners 80 kW .................................................................................... 33
■Burners 120/160 kW ........................................................................... 34
■Burners 200/240/280/318 kW ............................................................. 35
Inserting the coding card, fitting the top panels ..................................... 36
Connections on the heating water side .................................................. 36
■Making the safety connections ........................................................... 37
Flue gas connection ............................................................................... 37
■Connections on the flue gas side ....................................................... 37
Connecting the condensate drain .......................................................... 38
■Condensate drain ............................................................................... 38
■Connecting the neutralising system (accessories) ............................. 38
Fitting the front panel ............................................................................. 39
Commissioning and adjustment ............................................................. 39
4. Appendix Connection and wiring diagram ............................................................. 40
Specification .......................................................................................... 41
Index
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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.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
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
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic 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, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Disposal of packaging
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Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
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.
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
Conversion for other countries
The Vitocrossal 100 may only be delivered to the
countries specified on the type plate. For deliveries to
other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
Intended use (cont.)
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Clearance dimensions
700
500
1000
500
Fig. 1
Delivery and handling
The boiler is delivered on a wooden pallet.
The following components are delivered in individual
packages:
■Casing and thermal insulation; see Fig. 4
■MatriX cylinder burner
■Control unit
■Cable set
■Programming module
■Programming unit
■Set with technical documentation
■Venturi extension, part of standard delivery only for
burners from 200 kW and open flue operation
A
C
B
Fig. 2
1. Remove bag with boiler flue connection, flue gas
temperature sensor, retaining bracket and trap and
put aside.
2. Position the ramp against the pallet.
3. Remove the transport brackets.
4. Roll the boiler down the ramp backwards in a
straight line.
Danger
The boiler can cause serious injury if it over-
turns.
At least 2 people are required to move the
boiler. Roll the boiler in a straight line.
Alternative transport aids
ACrane lug
B4 holes to slide poles through for lifting
COption for pallet truck insertion underneath
Preparing for installation
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Transport dimensions
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.
With boiler sizes up to 160 kW, base rail A and retain-
ing bracket with castor B can be taken off if passage-
ways are particularly narrow. In such cases, the boiler
then has to be moved at an angle with a transport aid.
a
B A
Fig. 3
ABase rail
BRetaining bracket with castor
Handling dimension a
kW 80 120 and 160
mm 450 570
Preparing for installation (cont.)
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Thermal insulation and casing parts
A
B
C
B
C
D
E
F
G
H
K
L
M
O
N
P
R
T
S
Fig. 4
AFront panel
BSide panel
CFixing rail
DFront cover
EThermal insulation mat, bottom front
FThermal insulation mat, centre front
GThermal insulation mat, top front
HThermal insulation jacket
KThermal insulation mat, bottom back
LThermal insulation mat, centre back
MThermal insulation mat, top back
NControl panel
OShield panel
PTop panel, front
RTop panel, back
SBack panel, top
TBack panel, bottom
Preparing for installation (cont.)
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!Please note
Damage to the flue gas connection can result in
leaks.
Never lift or move the boiler by the flue gas con-
nection.
Note
A suitable condensate drain must be available in the
installation room if the boiler is installed at ground level
(max. 50 mm above the floor).
±15mm
Fig. 5
Level the boiler with its adjustable feet.
Note
Extend the adjustable feet until the castors are free of
load.
If a neutralising system is being fitted, wind out the
adjustable feet as far as possible.
Note
Special foundations are not required.
Siting and levelling the boiler
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Note
All required components are included in the thermal
insulation box.
1.
2.
3.
A
Fig. 6
AHoles for spring hooks, upper thermal insulation
mat
Secure thermal insulation sections with spring hooks.
Fitting the thermal insulation
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