Viessmann Vitocrossal User manual

Installation instructions
for contractors
VIESMANN
Vitocrossal
Type CI, 80 to 318 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
VITOCROSSAL
5814780 GB 2/2018 Dispose after installation.

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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
■Boiler water 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.
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.
Disposal of packaging
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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, type CI, 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
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, part of standard delivery only for
burners from 200 kW and open flue operation
A
C
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
ACrane lug
B4 holes to slide poles through for lifting
COption for pallet truck insertion underneath
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
A
B
C
B
C
D
E
F
G
H
K
L
M
O
N
P
R
T
S
Fig. 3
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 unit panel
OShield panel
PTop panel, front
RTop panel, back
Preparing for installation (cont.)
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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. 4
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. 5
AHoles for spring hooks, upper thermal insulation
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.
4x
M10x30
A
B
Fig. 6 Burners 80 kW
AVentilation air connection
BGas connection
!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.
Insert the burner. Secure screws by hand. Tighten the
screws diagonally with a torque of 10 Nm.
Mounting the burner
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4x
M10x30
A
B
C
Fig. 7 Burners 120 - 318 kW
AGas connection
BVentilation air connection
CVenturi 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. The burner gauze
assembly, electrodes and insulation block must
not be damaged.
Insert the burner. Secure screws by hand. Tighten the
screws diagonally with a torque of 10 Nm.
Mounting the burner (cont.)
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Note
The illustrations show how the gas supply pipe 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 = Height between top edge of gas pipe and top
edge of base rail of the boiler max. 60 mm.
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
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].
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
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.
Burner connections on the gas side
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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
"Accessories for room sealed operation" installa-
tion instructions
Fitting the set for room sealed operation (cont.)
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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° boiler flue connection.
Check the flue gas connection for tightness.
A
1.
3.
2.
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.
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 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.
Always fill the trap with water before commis-
sioning.
Fitting the trap
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3.
2.
1.
4.
5. 2x
6.
Fig. 19
1. Insert M 6 x 10 screws. Hook the rails into place.
Tighten the screws.
2. Position the bottom of the side panels in the rails.
Hook the top of the side panels into the top rails on
the boiler.
If the gas line is to be routed along the side, break
out the perforated section in the side panel using
pliers.
3. Hook the back panel into the side panels.
If the gas line is to be routed to the back, break out
the relevant perforated section using pliers.
Loosely secure side panels with screws M6 x 10.
4. Hook the top back panel into the side panels.
5. Click the edge protectors into place.
6. Affix the type plate to the left or right side panel.
Fitting the side and back panels
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