Viessmann CI1, Installation Instructions For Contractors

Page 1: ...ructions 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 5792 916 GB 3 2017 Dispose after installation ...

Page 2: ...lations 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 a ÖNORM EN ÖVGW G K directives ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF ...

Page 3: ...it 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 ...

Page 4: ...ses 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 o...

Page 5: ... 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 ...

Page 6: ...0 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 th...

Page 7: ...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 A Base rail B Retaining bracket with castor Handling dimension a kW 80 120 and 160 mm 450 570 Preparing for installation cont 5792 916 GB ...

Page 8: ...ttom front F Thermal insulation mat centre front G Thermal insulation mat top front H Thermal insulation jacket K Thermal insulation mat bottom back L Thermal insulation mat centre back M Thermal insulation mat top back N Control panel O Shield panel P Top panel front R Top panel back S Back panel top T Back panel bottom Preparing for installation cont 5792 916 GB ...

Page 9: ...e 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 5792 916 GB ...

Page 10: ...ed components are included in the thermal insulation box 1 2 3 A Fig 6 A Holes for spring hooks upper thermal insulation mat Secure thermal insulation sections with spring hooks Fitting the thermal insulation 5792 916 GB ...

Page 11: ...on 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 5792 916 GB ...

Page 12: ... 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 5792 916 GB ...

Page 13: ...A Fig 9 Boilers up to 80 kW A Fig 10 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...

Page 14: ...rs up to 80 kW Fig 12 Boilers up to 80 kW a Fig 13 Boilers 120 to 318 kW Fig 14 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 5792 916 GB ...

Page 15: ...ection 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 closin...

Page 16: ...installa tion instructions Position of the ventilation air pipe A Fig 15 Boilers up to 80 kW A Ventilation air connection A Fig 16 Boilers 120 to 160 kW A Ventilation air pipe with adaptor Fitting the set for room sealed operation 5792 916 GB ...

Page 17: ...17 A Fig 17 Boilers 200 to 318 kW A Ventilation air pipe with adaptor Accessories for room sealed operation installa tion instructions Fitting the set for room sealed operation cont 5792 916 GB ...

Page 18: ...er may only be operated with the original 90 boiler flue connection Check the flue gas connection for tightness A 1 3 2 Fig 18 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 5792 916 GB ...

Page 19: ... 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 5792 916 GB ...

Page 20: ...ng 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 ...

Page 21: ...The screws serve to secure the control unit module to the boiler 3 1 2 Fig 22 Installing the control unit 2 1 3 B A Fig 23 1 Insert screws only loosely 2 Fit edge protectors 3 Screw shield panel A to control unit panel B 4 5 Fig 24 4 Position control unit on the screws 5 Tighten the screws Assembling the control unit 5792 916 GB ...

Page 22: ... is routed over 2 retainers For connection see connection and wiring diagram on page 40 Connecting the internal connecting cables to the control unit Route the cables into the control unit using the strain relief fittings Applying strain relief 1 2 4 3 Fig 26 Strip max 100 mm of insulation from the cables Installing the control unit cont 5792 916 GB ...

Page 23: ...nel 11 X9 X8 35 54 100 Fig 28 Internal connections to the control unit Danger Incorrectly executed electrical installations can result in injuries from electrical current and dam age to the appliance Route LV leads and cables 42 V 230 V sepa rately Connecting the internal connecting cables to cont 5792 916 GB ...

Page 24: ...ble harness Boiler water and flue gas tempera ture sensor fan control Plug 230 V dG Gas train gF Ignition unit a Ö Fan Fitting the control unit to the boiler Please note Hot components can damage electrical cables Never route electrical cables near hot compo nents Observe the maximum permissible tem peratures for the cables Connecting the internal connecting cables to cont 5792 916 GB ...

Page 25: ...ack along the boiler top rail use cable clamps For connection of the flue gas temperature sensor to the flue outlet see the fol lowing chapter Danger Incorrectly executed electrical installations can result in injuries from electrical current and dam age to the appliance Route LV leads and cables 42 V 230 V sepa rately Please note Hot components can damage electrical cables Never route electrical ...

Page 26: ...26 Fig 31 Insert the connector at the prefitted flue gas tempera ture sensor in the boiler flue connection Connecting the flue gas temperature sensor 5792 916 GB ...

Page 27: ... 21 1 0 10 V Fig 32 Plug 230 V sÖ Boiler circuit pump or butterfly valve with return spring only with multi boiler system Rated voltage 230 V Rated current Max 2 1 A sA Circulation pump for cylinder heating B Rated voltage 230 V Rated current Max 2 1 A sK DHW circulation pump accessories Rated voltage 230 V Rated current Max 2 1 A Connecting external cables 5792 916 GB ...

Page 28: ...t room accessories out side the wet area must not be connected to the power supply at the control unit If the boiler is not sited in a wet room the power supply for accessories can be connected at the control unit This connection is directly controlled with the system ON OFF switch max 6 A LV plug Outside temperature sensor Installation North or north westerly wall 2 to 2 5 m above ground level on...

Page 29: ...r buf fer cylinder 30 0 boiler 2 Ext In 2 6 12 12 2 6 Recommended for Δt 15 K 49 kW 2 2 80 m3 h 60 kW 3 3 44 m3 h Self regulating pump Pump is switched on and off via plug sÖ B sÖ L N C N A L D Fig 34 A Pump B To the control unit C Contactor D Separate power supply observe manufacturer s instructions Circulation pump at plug sA A 1 M sA L N Fig 35 A Circulation pump Note Connect DHW circulation pu...

Page 30: ... 0 75 mm2 External demand via switching contact Connection options EA1 extension accessory see separate installation instructions Plug lH When the contact is closed burner operation is load dependent The boiler water is heated to the set value selected in coding address 9b in group General 1 The boiler water temperature is limited by this set value and by the electronic maximum limit coding addres...

Page 31: ...sated control units Effect of the function on the circulation pump for cylin der heating coding address 5F in group DHW 3 External demand via 0 10 V input Connection at 0 10 V input at EA1 extension Ensure DC separation between the earth conductor and the negative pole of the on site power source U L N L N fÖ S P aBJ Ö 0 10V f A Fig 38 0 to 1 V No specification for set boiler water temperature 1 V...

Page 32: ...ing address d6 in group Heating circuit only for weather compensated control units Effect of the function on the circulation pump for cylin der heating coding address 5E in group DHW 3 Connection of accessories fÖ fÖ B C aVG fÖ lH A D E aVG aVG f A aVG aVG f A fÖ aVG aVG f A Fig 39 A Boiler control unit B Extension kit for heating circuit with mixer M2 C Extension kit for heating circuit with mixe...

Page 33: ... Ö A a A a Ö a A aY A A Fig 40 LV plug aA Ionisation electrode a ÖA Fan control a Ö a ÖA Gas train modulation coil control A Combustion chamber pressure limiter Plug 230 V dG dGA Gas train a Ö Fan and ignition unit gF Ignition unit aAA Digital flame amplifier Burner electrical connection 5792 916 GB ...

Page 34: ...ig 41 LV plug aA Ionisation electrode a ÖA Fan control a Ö Gas train modulation coil control A Combustion chamber pressure limiter Plug 230 V dG Gas train a Ö Fan gF Ignition unit aAA Digital flame amplifier Burner electrical connection cont 5792 916 GB ...

Page 35: ... Fig 42 LV plug aA Ionisation electrode a ÖA Fan control a Ö Gas train modulation coil control A Combustion chamber pressure limiter Plug 230 V dG Gas train a Ö Fan gF Ignition unit aAA Digital flame amplifier Burner electrical connection cont 5792 916 GB ...

Page 36: ... C Drain R 1 D Boiler return up to 160 kW DN 50 160 kW DN 65 E Safety valve R 1 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 Connect the pipework free of l...

Page 37: ...h the system version Flue gas connection Only carry out commissioning when the following conditions have been met Unrestricted flow in the flue gas routes Positive pressure flue system is gas tight Inspection port covers checked for secure and tight seating Apertures for supplying sufficient combustion air are open and cannot be closed All current regulations on installing and commission ing flue ...

Page 38: ...utralising system B C A Fig 45 A Drain hose from trap to neutralising system external 7 of connection 17 mm B Drain hose from neutralising system to drainage system C Neutralising system C Fig 46 Position of neutralising system C 1 Place neutralising system C under the boiler from the front Use a long drain hose A so that the neutralising system can be pulled out forwards 2 Loosely route drain hos...

Page 39: ...stud into the front panel and secure 3 Position the front panel in the lower rim and flip it shut tightly 4 Secure the front panel with 2 screws M 5 x 25 5 Push the front panel closed Commissioning and adjustment Vitocrossal 100 type CI1 service instructions and boiler control unit operating instructions Fitting the front panel 5792 916 GB ...

Page 40: ... header accessories Cylinder temperature sensor sÖ Boiler circuit pump or butterfly valve with return spring sA Circulation pump either Circulation pump for cylinder heating External heating circuit pump DHW circulation pump Code 39 Connection and wiring diagram 5792 916 GB ...

Page 41: ... TR 80 60 kW 15 74 29 110 29 146 44 184 44 220 58 258 58 291 Rated heat input kW 76 113 151 189 226 264 300 Product ID CE 0085CR0391 Permiss operating temper ature C 95 Permiss flow temperature safety temperature C 110 Max permiss operating pressure bar 6 MPa 0 6 Min permiss operating pressure bar 0 5 MPa 0 05 Test pressure bar 7 8 MPa 0 78 Boiler body dimensions Length handling dimension 1 mm 660...

Page 42: ... return tem perature of 60 C C 65 65 65 65 65 65 65 Mass flow rate for natural gas At rated heating output kg h 120 180 240 300 360 420 477 At partial load kg h 36 54 72 90 108 126 143 Flue gas connection DN 200 200 200 200 200 200 200 Draught at mbar 0 7 0 7 0 7 0 7 0 7 0 7 0 7 flue outlet Pa 70 70 70 70 70 70 70 Product parameters ac cording to EnEV Standard seasonal efficien cy to DIN For heati...

Page 43: ...43 5792 916 GB ...

Page 44: ...hropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5792 916 GB Subject to technical modifications ...