Viessmann Vitocrossal User manual

Installation instructions
for contractors
VIESMANN
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
5839853 GB 7/2020 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
5839853

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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.)
5839853

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1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Product information Product information ................................................................................ 6
System examples .................................................................................. 6
Conversion for other countries ............................................................... 6
3. Preparing for installation ................................................................................................................ 7
4. Installation sequence Siting and levelling the boiler ................................................................. 9
Removing the front panel ....................................................................... 9
Fitting the gas supply pipe (accessories) ............................................... 10
■Routing options for the gas supply pipe ............................................. 10
Burner connections on the gas side ...................................................... 12
Fitting the set for room sealed operation .............................................. 13
Fitting the boiler flue connection ............................................................ 14
Fitting the trap and flue gas temperature sensor ................................... 16
■Condensate drain ............................................................................... 16
Connecting the neutralising system (accessories) ................................ 16
Fitting the front panel ............................................................................. 17
Boiler electrical connection .................................................................... 18
■Opening the control unit ..................................................................... 18
■Routing cables and leads ................................................................... 19
■External cables ................................................................................... 20
■Circulation pump at plug sÖ ................................................................ 22
■Circulation pump at plug sA ................................................................ 23
■Pumps with power consumption greater than 2 A or connection for
HE pump ............................................................................................. 24
■Pumps 400 V~ .................................................................................... 24
■External demand via switching contact .............................................. 24
■External demand via 0 – 10 V input .................................................... 25
■External blocking via switching contact .............................................. 25
■Connection of accessories ................................................................. 26
Electrical connection of the motorised flue gas damper in multi boiler
systems .................................................................................................. 27
Fitting the top panels ............................................................................. 27
Connections on the heating water side .................................................. 28
Flue gas connection ............................................................................... 29
■Connections on the flue gas side ....................................................... 29
Commissioning and adjustment ............................................................. 29
5. Appendix Connection and wiring diagram ............................................................. 30
Specification .......................................................................................... 31
■Boiler specification .............................................................................. 31
■MatriX cylinder burner specification .................................................... 33
Index
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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.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Disposal of packaging
5839853

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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.
Product information
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Clearance dimensions
700
500
1000
500
Fig. 1
Delivery and handling
The boiler is delivered on a wooden pallet.
To facilitate handling, rigid castors are fitted at the back
and a swivel castor at the front of the boiler. Leave the
adjustable feet fully inserted whilst moving the boiler.
Including casing, the minimum handling dimension is
750 mm (for all output sizes).
B
4x
A
Fig. 2
1. Remove the protective foil, edge protection and the
top board.
2. Position ramp A against the pallet.
3. Remove transport brackets B.
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.
Preparing for installation
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The boiler is equipped with further transport aids
BA
Fig. 3
Alternative transport aids
A4 holes to slide poles (to be provided by the cus-
tomer) through as a transport aid
Remove the top back panel and the front panel
(see page 9).
BLifting eye (from 120 kW)
Remove top panels; see page 18.
Reducing the handling dimensions
The casing and certain other components can be
removed to reduce the handling dimensions. If passa-
geways are particularly narrow, the boiler can also be
delivered in individual components.
Preparing for installation (cont.)
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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
Fig. 4
Extend the adjustable feet until the castors are free of
load.
Level the boiler with its adjustable feet.
Note
If a neutralising system is being fitted, wind out the
adjustable feet as far as possible.
Note
Special foundations are not required.
Removing the front panel
The front panel has to be removed to fit the gas supply
pipe, as well as the room sealed set and neutralising
system (accessories).
1.
3.
2.
Fig. 5
1. Tip the front panel forward slightly at the top.
2. Undo the locking screws until the front panel can
be removed.
Siting and levelling the boiler
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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
Position of the gas supply pipe
To provide a better overview, the boiler is shown in the
drawings without its casing.
A
Fig. 6 Boilers 80 kW
A
Fig. 7 Boilers from 120 kW
!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.
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. 8 Boilers up to 80 kW
Fig. 9 Boilers up to 80 kW
a
Fig. 10 Boilers from 120 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. 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.)
5839853

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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
From 120 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 pipes for room sealed operation
To provide a better overview, the boiler is shown in the
drawings without its casing.
A
Fig. 12 Boilers up to 80 kW
AVentilation air connection
A
Fig. 13 Boilers 120 to 160 kW
AVentilation air pipe with adaptor
Fitting the set for room sealed operation
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A
Fig. 14 Boilers from 200 kW
AVentilation 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. 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.
Fitting the set for room sealed operation (cont.)
5839853

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A
3.
2.
1.
Fig. 15
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 (cont.)
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Fig. 16
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.
Condensate drain
■Connect the trap with the plastic hose to the drain-
age system.
■Route the condensate drain with a fall and below the
anti-flooding level of the flue gas collector.
■The condensate drain must be freely accessible for
inspection where it enters the drainage system.
■External 7 of connection: 17 mm
Danger
Flue gas escaping from the trap can cause
potentially fatal carbon monoxide poisoning.
Always fill the trap with water before commis-
sioning.
Connecting the neutralising system (accessories)
Installation instructions "Neutralising system"
Fitting the trap and flue gas temperature sensor
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C
B
A
Fig. 17
ADrain hose from trap to neutralising system,
external 7 of connection: 17 mm
BDrain hose from neutralising system to drainage
system
CNeutralising system
1. Position neutralising system C behind the boiler.
2. Connect drain hose A to the trap.
3. Connect neutralising system drain hose B to the
drainage system.
Fitting the front panel
3.
1.
2.
Fig. 18
2. Secure the front panel with the screws.
Connecting the neutralising system (accessories) (cont.)
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Opening the control unit
2.
1.
4.
3.
Fig. 19
Boiler electrical connection
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Routing cables and leads
A
B
Fig. 20
AExternal LV leads
B230 V power cable
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.
■Route extra low voltage (ELV) leads A and
> 42 V/230 V∼ cables B separately.
■Strip as little of the insulation as possible,
directly above the terminals, and bundle tightly
to the corresponding terminals.
■Secure cables with cable ties.
When connecting external switching contacts and on-
site components, observe the insulation requirements
of IEC/EN 60335-1.
!Please note
An electrostatic charge may damage electronic
assemblies.
Before beginning work, touch an earthed object
such as heating or water pipes to discharge any
static.
Applying strain relief
Provide strain relief for cables that do not have any;
see Fig. 21. Insert cables with moulded strain relief
into the casing recess; see Fig. 22.
1.
2.
4.
3.
Fig. 21 Strip max. 100 mm of insulation from the
cables.
Boiler electrical connection (cont.)
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Cables with moulded strain relief
1.
2.
2.
Fig. 22
External cables
Information on connecting accessories
Accessory installation instructions supplied with
accessories.
Boiler electrical connection (cont.)
5839853