Viessmann Vitocrossal, Installation Instructions Manual

Page 1: ...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 ...

Page 2: ...s 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...

Page 3: ...rk 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 ...

Page 4: ...ting 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 ...

Page 5: ...o 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 Intend...

Page 6: ...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 infor...

Page 7: ... the boiler Including casing the minimum handling dimension is 750 mm for all output sizes B4x 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 boi...

Page 8: ...d Remove the top back panel and the front panel see page 9 B Lifting 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 5839853 ...

Page 9: ... 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 p...

Page 10: ...s 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 ou...

Page 11: ... 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 ...

Page 12: ...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 Not...

Page 13: ...pes 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 A Ventilation air connection A Fig 13 Boilers 120 to 160 kW A Ventilation air pipe with adaptor Fitting the set for room sealed operation 5839853 ...

Page 14: ...ction 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 ...

Page 15: ... 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 5839853 ...

Page 16: ...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 instruct...

Page 17: ... to drainage system C Neutralising 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 5839853 ...

Page 18: ...18 Opening the control unit 2 1 4 3 Fig 19 Boiler electrical connection 5839853 ...

Page 19: ...e 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 r...

Page 20: ...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 ...

Page 21: ...ted 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 fÖ Power supply on output extension SA 169 Danger Incorrect core assignment can result in seri ous injury and damage to the appliance Take care not to interchange wires L1 and N Boiler electrical connection cont...

Page 22: ...boiler is sited in a wet 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 ...

Page 23: ... header or heating water buf fer cylinder 30 0 boiler 2 Ext In 2 6 12 12 2 6 Self regulating pump Pump is switched on and off via plug sÖ B sÖ L N C N A L D Fig 25 A Pump on site B To the control unit C Contactor on site D Separate power supply observe manufacturer s instructions Circulation pump at plug sA A 1 M sA L N Fig 26 A Circulation pump Note Connect DHW circulation pumps with standalone f...

Page 24: ...05RN F3G 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 parameter coding address 9b in the General 1 group The boiler water temperature is limited by this set value and by the electronic maxi ...

Page 25: ...ly for weather compensated control units Effect of the function on the circulation pump for cylin der heating Parameter coding address 5F in the DHW 3 group 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 29 0 to 1 V No specification f...

Page 26: ...ion on the heating circuit pump Parameter coding address d6 in the Heating cir cuit group only for weather compensated control units Effect of the function on the circulation pump for cylin der heating Parameter coding address 5E in the DHW 3 group 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 30 A Boiler control unit B Extension kit for heating cir...

Page 27: ...nnection set Note If there is a separate flue system for each boiler no flue gas damper is required Multi boiler systems with up to 4 boilers In multi boiler systems with up to 4 boilers connected to a common flue the relay box connection set and the motorised flue gas damper from the accessories range are required for each boiler Installation instructions for Relay box connec tion set Fitting the...

Page 28: ... 3 and 4 bar 0 3 0 4 MPa Up to 160 kW R 1 3 and 4 bar 0 3 0 4 MPa From 200 kW R 1 6 bar 0 6 MPa R 1 Safety valve discharge pipe 3 and 4 bar 0 3 0 4 MPa Up to 160 kW R 1 3 and 4 bar 0 3 0 4 MPa From 200 kW R 1 6 bar 0 6 MPa R 1 Please note Connections subject to mechanical loads can cause appliance damage Connect the pipework free of load and tor que stress 2 Check the connections on the heating wa...

Page 29: ...ue gas Ensure the flue system functions correctly Aper tures for combustion air supply must not be able to be closed off Prevent condensate drainage via a wind protec tor Connections on the flue gas side Note Ensure the flue gas connection is free of load and tor que stress Flue system installation instructions Flue gas connection 7 200 mm Please note Balanced or standard flues must not come loose...

Page 30: ...der temperature sensor sÖ Setting for heating circuit pump boiler circuit pump or butterfly valve Code 37 sA Circulation pump either Circulation pump for cylinder heating External heating circuit pump DHW circulation pump Code 39 Connection and wiring diagram 5839853 ...

Page 31: ...cation Rated heating output range Pcond TF TR 50 30 kW 16 80 32 120 32 160 48 200 48 240 64 280 64 318 Pn TF 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 tempera ture C 95 Permiss flow temperature safety temperature C 110 Max permiss operating pres sure bar 6 MPa 0 6 Min permiss operating pres ...

Page 32: ...tput C 45 45 45 45 45 45 45 At partial load C 35 35 35 35 35 35 35 Temperature at a 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 Pa 80 120 120 110 110 140 140 Flue outlet mbar 0 8 1 2 1 2 1 1 1 1 1 4...

Page 33: ...e CI 75 80 kW CI 120 160 kW CI 120 160 kW CI 200 240 kW CI 200 240 kW CI 280 318 kW CI 280 318 kW Product ID See boiler Voltage V 230 Frequency Hz 50 Power consumption At upper heating output W 140 5 130 268 171 279 260 393 At lower heating output W 19 5 28 28 29 29 26 5 26 5 Version Modulating Dimensions Width a mm 463 426 426 463 463 463 463 Length b mm 442 481 481 655 655 731 731 Height c mm 40...

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Page 36: ... Shropshire 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 5839853 Subject to technical modifications ...