Viessmann VITOCROSSAL Series Installation Instructions Manual Download Page 1

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Installation instructions

for contractors

VIESMANN

Vitocrossal
Type CIB, 80 to 318 kW

Gas condensing boiler with MatriX cylinder burner

Open flue

and

room sealed

operation

VITOCROSSAL

5839818 GB

9/2019

Dispose after installation.

Summary of Contents for VITOCROSSAL Series

Page 1: ...nstructions for contractors VIESMANN Vitocrossal Type CIB 80 to 318 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation VITOCROSSAL 5839818 GB 9 2019 Dispose after...

Page 2: ...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 lat...

Page 3: ...k 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 sys...

Page 4: ...rol unit to the boiler 25 Connecting the flue gas temperature sensor 26 Fitting the back panels 26 Boiler water temperature sensor and water pressure switch 27 Connecting external cables 28 Circulatio...

Page 5: ...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 servi...

Page 6: ...nder 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...

Page 7: ...tion A 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...

Page 8: ...S T R P N O H G F E D C B C B A Fig 3 A Front panel B Side panel C Guide rail D Front cover E Thermal insulation mat bottom front F Thermal insulation mat centre front G Thermal insulation mat top fr...

Page 9: ...m if the boiler is installed at ground level max 50 mm above the floor 15 mm A Fig 4 A Spirit level to align the boiler Level the boiler with its adjustable feet Note Extend the adjustable feet until...

Page 10: ...components are included in the thermal insulation box 1 2 A Fig 5 A Holes for spring hooks for top front thermal insula tion mat Secure thermal insulation sections with spring hooks Fitting the therma...

Page 11: ...ection 1 Insert the burner 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 gau...

Page 12: ...ation in separate box 1 Insert the burner Please note Mechanical damage to delicate components will impair the burner function Exercise great care when inserting the burner into the combustion chamber...

Page 13: ...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 opt...

Page 14: ...120 to 318 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 operat...

Page 15: ...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...

Page 16: ...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 th...

Page 17: ...17 A Fig 16 Boilers 200 to 318 kW A Ventilation air pipe with adaptor Fitting the set for room sealed operation cont 5839818...

Page 18: ...nly be operated with the original 90 boiler flue connection Check the flue gas connection for tightness A 3 2 1 Fig 17 1 Hook in the retaining bracket 2 Push the boiler flue connection onto the flue o...

Page 19: ...e condensate drain to the neutralising sys tem if installed see page 39 Note The boiler may only be operated with the original trap Danger Flue gas escaping from the trap can cause potentially fatal c...

Page 20: ...the side panels in the guide rails Secure the side pan els loosely to the head rail of the boiler using 4 self tapping screws M 6 x 12 The side panels will be aligned later Note If gas pipes are to b...

Page 21: ...re the control unit module to the boiler 3 1 2 Fig 21 Installing the control unit 1 2 3 2x A B Fig 22 1 Insert screws 4 8 x 9 5 only loosely 2 Fit edge protectors 3 Screw shield panel A to control uni...

Page 22: ...tion and wiring diagram on page 41 Connecting the internal connecting cables to the control unit Route the cables into the control unit Provide strain relief for cables that do not have any see Fig 25...

Page 23: ...and 42 V 230 V cables B separately Strip as little of the insulation as possible directly above the terminals Bundle the cables close to the corresponding terminals Secure cables with cable ties When...

Page 24: ...lue gas temper ature sensor fan control X9 Gas train modulation coil control a for boilers up to 80 kW additionally a A combustion cham ber pressure limiter and water pressure switch X19 Cylinder temp...

Page 25: ...e 33 34 onwards 4 Route the lead for the cylinder and flue gas tem perature sensor to the back along the boiler top rail use cable clamps Connect the flue gas tempera ture sensor to the flue outlet se...

Page 26: ...e gas temperature sensor Fig 30 Insert the connector at the prefitted flue gas tempera ture sensor in the boiler flue connection Fitting the back panels 1 2 3 2x Fig 31 Fitting the control unit to the...

Page 27: ...switch A B C D Fig 32 A Boiler water temperature sensor control unit plug X8 B Connection pressure gauge C Connection 1 safety valve safety equipment block D Water pressure switch control unit plug X...

Page 28: ...20 28 21 1 Fig 33 Plug 230 V s 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 heat...

Page 29: ...emand External blocking Power supply accessories 230 V 50 Hz Where 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...

Page 30: ...s 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 s B s L N C N A L D Fig 35 A Pump on site B To the control unit...

Page 31: ...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 de...

Page 32: ...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 Connectio...

Page 33: ...ction 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 heat...

Page 34: ...F dB dG a A a A a a A aY A A Fig 41 LV plug aA Ionisation electrode a A Fan control a a A Gas train modulation coil control A Combustion chamber pressure switch Plug 230 V dG dGA Gas train a Fan and i...

Page 35: ...Fig 42 LV plug aA Ionisation electrode a A Fan control a Gas train modulation coil control A Combustion chamber pressure switch Plug 230 V dG Gas train a Fan gF Ignition unit aAA Digital flame amplif...

Page 36: ...ccessory is required for each boiler In multi boiler systems with up to 2 boilers connected to a common flue the pressure switch connection set and the motorised flue gas damper from the accessories r...

Page 37: ...must be installed at zero volt The coding card is supplied in the burner packaging Fitting the top panels 2 1 4 8 x 9 5 Fig 45 2 Align the side panels parallel to the top panels and tighten the screw...

Page 38: ...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...

Page 39: ...drainage system Flue gas connection 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...

Page 40: ...tor Fitting the front panel 1 2 2x 3 4 5 Fig 48 1 Hook the bottom of the front panel into the base rail Secure the front panel with 2 self tapping screws M 6 x 12 2 Insert the location stud into the f...

Page 41: ...w loss header accessories Cylinder temperature sensor s Boiler circuit pump or butterfly valve with return spring sA Circulation pump either Circulation pump for cylinder heating External heating circ...

Page 42: ...5 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...

Page 43: ...ature 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...

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...

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