Viessmann VITOCROSSAL Series User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal
Type CIB, 80 to 318 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
VITOCROSSAL
5839818 GB 9/2019 Dispose after installation.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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
■Relevant country-specific safety regu-
lations
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, 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 recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch off the appliance and
let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
Safety instructions
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!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
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.
Safety instructions (cont.)
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1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
■System examples ............................................................................... 6
■Conversion for other countries ........................................................... 6
2. Preparing for installation ................................................................................................................ 7
3. Installation sequence Siting and levelling the boiler ................................................................. 9
Fitting the thermal insulation .................................................................. 10
Mounting the burner ............................................................................... 11
■Burners up to 80 kW ........................................................................... 11
■Burners from 120 to 318 kW ............................................................... 12
Fitting the gas supply pipe (accessories) ............................................... 13
■Routing options for the gas supply pipe ............................................. 13
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 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 ......................................................... 25
■Connecting the flue gas temperature sensor ...................................... 26
■Fitting the back panels ........................................................................ 26
■Boiler water temperature sensor and water pressure switch .............. 27
Connecting external cables ................................................................... 28
■Circulation pump at plug sÖ ................................................................ 29
■Circulation pump at plug sA ................................................................ 30
■Pumps with power consumption greater than 2 A or connection for
HE pump ............................................................................................. 31
■External demand via 0 – 10 V input .................................................... 32
■External blocking via switching contact .............................................. 32
■Connection of accessories ................................................................. 33
Burner electrical connection .................................................................. 34
■Burners up to 80 kW ........................................................................... 34
■Burners 120/160 kW ........................................................................... 35
■Burners 200/240/280/318 kW ............................................................. 36
Electrical connection of the motorised flue gas damper in multi boiler
systems .................................................................................................. 36
Inserting the coding card ....................................................................... 37
Fitting the top panels ............................................................................. 37
Connections on the heating water side .................................................. 38
Connecting the condensate drain .......................................................... 39
■Condensate drain ............................................................................... 39
■Connecting the neutralising system (accessories) ............................. 39
Flue gas connection ............................................................................... 39
■Connections on the flue gas side ....................................................... 39
Fitting the front panel ............................................................................. 40
Commissioning and adjustment ............................................................. 40
4. Appendix Connection and wiring diagram ............................................................. 41
Specification .......................................................................................... 42
Index
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Disposal of packaging
Please dispose of packaging waste in line with statu-
tory regulations.
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.
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.
Disposal of packaging
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Intended use also includes the adherence to mainte-
nance and inspection intervals.
Product information
Vitocrossal, type CIB, 80 to 318 kW with permissible
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
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. For deliveries to other
countries, approved contractors must arrange individ-
ual 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. 3
■MatriX cylinder burner
■Control unit
■Cable set
■Programming module
■Programming unit
■Set with technical documentation
■Venturi extension; required accessory for burners
from 200 kW and open flue operation
A
B
Fig. 2
1. Remove the bag and place to one side.
The bag contains the following:
■Boiler flue connection
■Flue gas temperature sensor
■Retaining bracket
■Trap
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
ALifting eye (from 120 kW)
B4 holes to slide poles (to be provided by the cus-
tomer) through as a transport aid
Preparing for installation
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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
S
T
R
P
N
O
H
G
F
E
D
C
B
C
B
A
Fig. 3
AFront panel
BSide panel
CGuide rail
DFront cover
EThermal insulation mat, bottom front
FThermal insulation mat, centre front
GThermal insulation mat, top front
HThermal insulation jacket
NControl unit panel
OShield panel (holder for control unit)
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).
±15 mm
A
Fig. 4
ASpirit level to align the boiler
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.
A
Fig. 5
AHoles for spring hooks for top front thermal insula-
tion mat
Secure thermal insulation sections with spring hooks.
Fitting the thermal insulation
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Note
All parts required for mounting the burner are con-
tained in the burner pack.
Burners up to 80 kW
4x
M 10 x 30
A
B
Fig. 6 Burners 80 kW
AVentilation air connection
BGas connection
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. The
burner gauze assembly, electrodes and
insulation block must not be damaged.
2. Tighten screws until finger-tight. Tighten the
screws diagonally with a torque of 10 Nm.
Mounting the burner
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Burners from 120 to 318 kW
Note
All parts required for mounting the burner are con-
tained in the burner pack.
4x
M 10 x 30
A
B
C
Fig. 7
AGas connection
BVentilation air connection
CVenturi extension; required accessory for burners
from 200 kW for open flue operation (in separate
box)
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. The
burner gauze assembly, electrodes and
insulation block must not be damaged.
2. Tighten screws until finger-tight. Tighten the
screws diagonally with a torque of 10 Nm.
3. Fit the Venturi extension for open flue operation
from 200 kW.
Mounting the burner (cont.)
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Note
The illustrations show how gas supply pipe A, provi-
ded as an accessory, should be routed.
"Gas supply pipe" installation instructions
!Please note
Mechanically loaded gas supply pipes lead to
leaks and appliance damage.
■When undoing or tightening gas connections,
counterhold with a second open-ended span-
ner.
■Ensure all gas connections are kept free of
load and torque stress.
A
Fig. 8 Boilers up to 80 kW
A
Fig. 9 Boilers 120 to 318 kW
Routing options for the gas supply pipe
If the Viessmann gas supply pipe (accessories) is not
used, select one of the following pipe routing options:
Routing options for the gas supply pipe
■To the side, left
■To the side, right
■To the back, through the boiler floor
Boiler casing pipe knock-out
On the relevant side or back panel, break out the panel
section along the perforation by tapping lightly with a
hammer.
Danger
Sharp edged metal panels can cause cuts.
Wear safety gloves.
Fitting the gas supply pipe (accessories)
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a
Fig. 10 Boilers up to 80 kW
Fig. 11 Boilers up to 80 kW
a
Fig. 12 Boilers 120 to 318 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. 60 mm
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.
Fitting the gas supply pipe (accessories) (cont.)
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Note
We recommend that you use the Viessmann gas sup-
ply pipe (accessories).
1. Connect the gas supply according to TRGI 2008
[or local regulations]. Observe EN ISO 228.
aConnect the gas supply according to ÖVGW-
TR Gas 2009 and the regionally applicable
Building Regulations.
cConnect the gas supply according to SVGW.
■Gas supply pressure: 20/25 mbar (2/2.5 kPa)
■Max. permiss. gas supply pressure: 30 mbar
(3 kPa)
■Gas connection:
Boiler size Connection
Up to 80 kW G 1
120 to 318 kW G 1½
!Please note
Mechanically loaded gas supply pipes lead
to leaks and appliance damage.
■When undoing or tightening gas connec-
tions, counterhold with a second open-
ended spanner.
■Ensure all gas connections are kept free of
load and torque stress.
2. Carry out a tightness test.
Note
Only use suitable and approved leak detection
agents (EN 14291) and devices for the tightness
test. Leak detection agents with unsuitable constit-
uents (e.g. nitrites, sulphides) can cause material
damage.
Remove residues of the leak detection agent after
testing.
!Please note
Excessive test pressure will damage the
burner and gas train.
Max. test pressure 150 mbar. If a higher
pressure is required for tightness tests, dis-
connect the burner and gas train from the
main supply pipe. Undo the fitting.
Note
Just closing the gas shut-off valve is not sufficient.
There is then a risk of pressure entering the valve.
Damage due to excessive test pressure is
excluded from our warranty.
3. Purge the gas line.
Note
The [German] Combustion Order stipulates that ther-
mally activated shut-off equipment must be installed in
the gas supply line.
If the gas line is contaminated (e.g. old pipes with cor-
rosion products), we recommend installing a gas filter
in the supply line.
Danger
Escaping gas can lead to explosions which may
result in serious injury.
Never purge the gas line through the boiler com-
bustion chamber.
Fitting the gas supply pipe (accessories) (cont.)
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"Accessories for room sealed operation" installa-
tion instructions
Position of the ventilation air pipe
A
Fig. 14 Boilers up to 80 kW
AVentilation air connection
A
Fig. 15 Boilers 120 to 160 kW
AVentilation air pipe with adaptor
Fitting the set for room sealed operation
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A
Fig. 16 Boilers 200 to 318 kW
AVentilation air pipe with adaptor
Fitting the set for room sealed operation (cont.)
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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° boiler flue connection.
Check the flue gas connection for tightness.
A
3.
2.
1.
Fig. 17
1. Hook in the retaining bracket.
2. Push the boiler flue connection onto the flue outlet
as far as it will go.
Note
Gaskets A have already been inserted in the
boiler flue connection.
Check the gaskets fit well.
3. Secure with two M 8 screws; torque 18 Nm.
Fitting the boiler flue connection
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1.
A
Fig. 18
ACondensate drain hose, 7 17 mm
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.
Always fill the trap with water before commis-
sioning.
Fitting the trap
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3.
2.
1.
4x
M 6 x 12
A
B
4x
M6 x 12
Fig. 19
1. Insert self-tapping screws (M6 x 12). Hook in the
guide rails. Tighten the screws.
2. To facilitate installation, place the bottom of the
side panels in the guide rails. Secure the side pan-
els loosely to the head rail of the boiler using 4
self-tapping screws (M 6 x 12). The side panels will
be aligned later.
Note
If gas pipes are to be routed along the side, break
out the perforated section in side panel B using
pliers.
3. Affix type plate A to the right or left side panel.
Fitting the side panels
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