Viessmann CI Installation Instructions Manual Download Page 1

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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.

Summary of Contents for CI

Page 1: ... 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 ...

Page 2: ...gulations 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 VK...

Page 3: ... 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 connectio...

Page 4: ...tic 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 ser...

Page 5: ...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 arrang...

Page 6: ...lue 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...

Page 7: ... O N P R T S Fig 3 A Front panel B Side panel C Fixing rail D Front cover E Thermal insulation mat bottom 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 unit panel O Shield panel P Top panel front R Top panel back Preparin...

Page 8: ...8 S Back panel top T Back panel bottom Preparing for installation cont 5814780 ...

Page 9: ...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 5814780 ...

Page 10: ...ired components are included in the thermal insulation box 1 2 3 A Fig 5 A Holes for spring hooks upper thermal insulation mat Secure thermal insulation sections with spring hooks Fitting the thermal insulation 5814780 ...

Page 11: ...tion 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 5814780 ...

Page 12: ...te 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 5814780 ...

Page 13: ...ss 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 pan...

Page 14: ...lers 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 5814780 ...

Page 15: ...etection 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 clos...

Page 16: ...n installa tion instructions Position of the ventilation air pipe A Fig 14 Boilers up to 80 kW A Ventilation air connection A Fig 15 Boilers 120 to 160 kW A Ventilation air pipe with adaptor Fitting the set for room sealed operation 5814780 ...

Page 17: ...17 A Fig 16 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 5814780 ...

Page 18: ...iler 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 5814780 ...

Page 19: ...he 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 5814780 ...

Page 20: ...long 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 sid...

Page 21: ...y The screws serve to secure the control unit module to the boiler 3 1 2 Fig 21 Installing the control unit 2 1 3 B A Fig 22 1 Insert screws only loosely 2 Fit edge protectors 3 Screw shield panel A to control unit panel B 4 5 Fig 23 4 Position control unit on the screws 5 Tighten the screws Assembling the control unit 5814780 ...

Page 22: ...le 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 25 Strip max 100 mm of insulation from the cables Installing the control unit cont 5814780 ...

Page 23: ...panel 11 X9 X8 35 54 100 Fig 27 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 5814780 ...

Page 24: ...Cable 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 5814780 ...

Page 25: ... back 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 electrica...

Page 26: ...efitted flue gas tempera ture sensor in the boiler flue connection Boiler water temperature sensor A Fig 31 A Boiler water temperature sensor Insert the connector at the prefitted boiler water tem perature sensor in the boiler floor Fitting the control unit to the boiler cont 5814780 ...

Page 27: ...28 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 5814780 ...

Page 28: ...e the 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 t...

Page 29: ...ter 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 ...

Page 30: ...m2 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 mum limit codin...

Page 31: ...nly 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 38 0 to 1 V No specification ...

Page 32: ...tion 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 39 A Boiler control unit B Extension kit for heating ci...

Page 33: ... a 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 5814780 ...

Page 34: ... Fig 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 5814780 ...

Page 35: ... A 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 5814780 ...

Page 36: ... R 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...

Page 37: ...ection Do not carry out commissioning until the following conditions are met Free passage through the flue gas pipes Flue system with positive pressure is gas tight Inspection port covers checked for secure and tight seating Apertures for ensuring sufficient combustion air sup ply are open and cannot be closed off Applicable regulations on installing and commission ing flue systems have been follo...

Page 38: ...stem 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 The neutralising system is pulled out forwards for maintenance For this reason a long drain hose A should be used 2 Loose...

Page 39: ...tion 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 type CI service instructions and boiler control unit operating instructions Fitting the front panel 5814780 ...

Page 40: ...ss 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 5814780 ...

Page 41: ...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 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 6...

Page 42: ... 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 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 hea...

Page 43: ...43 5814780 ...

Page 44: ... 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 5814780 Subject to technical modifications ...

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