Viessmann VITOCROSSAL 200 CI2 Series Installation Instructions Manual
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Viessmann VITOCROSSAL 200 CI2 Series Installation Instructions Manual

Viessmann VITOCROSSAL 200 CI2 Series Installation Instructions Manual

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Installation Instructions
for use by heating contractor
Vitocrossal 200 CI2 series
Gas condensing boilers with MatriX cylinder burners
Heating input: 399 to 2000 MBH
(117 to 586 kW)
VITOCROSSAL 200
H
6175 796 - 07
10/2022
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann VITOCROSSAL 200 CI2 Series

  • Page 1 Installation Instructions for use by heating contractor Vitocrossal 200 CI2 series Gas condensing boilers with MatriX cylinder burners Heating input: 399 to 2000 MBH (117 to 586 kW) VITOCROSSAL 200 Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference.

  • Page 2: Safety, Installation And Warranty Requirements

    Once the installation work is complete, the heating installation of carbon monoxide detectors. Follow the contractor must familiarize the system operator/ Viessmann maintenance schedule of the boiler contained ultimate owner with all equipment, as well as safety in this manual.
  • Page 3 8 in this manual. - Wash work clothes separately from other clothing. Viessmann recommends installation of an additional Rinse washer thoroughly. electrical disconnect switch and a fuel shut-off valve (if - Operations such as sawing, blowing, tear-out and...

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 200 CI2 Installation Page Safety Safety, Installation and Warranty Requirements .... 2 General Information Important Regulatory and Installation Requirements ..5 About these Installation Instructions ......7 Intended Use .............7 Mechanical Room ............8 For Retrofit Applications ..........8 Preinstallation Recommended Minimum Service Clearances ....9 Unpacking the Boiler ..........10 Placement of Boiler ..........

  • Page 5: Important Regulatory And Installation Requirements

    General Information Vitocrossal 200 CI2 Installation Important Regulatory and Installation Requirements For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
  • Page 6 The gas valve of this boiler meets the advise the system operator/ultimate owner where requirements as set forth in the ASME CSD-1 standard. the literature can be found. Contact Viessmann for additional copies. IRI (Industrial Risk Insurers)

  • Page 7: About These Installation Instructions

    General Information Vitocrossal 200 CI2 Installation About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below. Warnings draw your attention to the presence of WARNING potential hazards or important product information.

  • Page 8: Mechanical Room

    General Information Vitocrossal 200 CI2 Installation Mechanical Room Use the installation room exclusively for the installation The Vitocrossal 200, CI2 boiler should be located in a of the boiler. heated indoor space. The boiler should also be located Site the boiler on a load bearing foundation with a near a floor drain and as close as possible to the vertical minimum height of 4 in.

  • Page 9: Recommended Minimum Service Clearances

    Preinstallation Vitocrossal 200 CI2 Installation Recommended Minimum Service Clearances To enable convenient installation and maintenance, observe the stated recommended minimum service clearance dimensions. 1000 1500 2000 Model 2 in. 1 in. 1000 1000 1000 1000 1000 1000 Top in. clearance 1 in multiboiler installations, clearance between boilers can be reduced to 0”...

  • Page 10: Unpacking The Boiler

    Preinstallation Vitocrossal 200 CI2 Installation Unpacking the Boiler The boiler is delivered on a wooden pallet. Note: The boiler can be lifted by crane only while it is still packed on the skid. Remove packaging unscrew the transport brackets. Position the ramp at the front of the boiler. Ensure that there is sufficient room to unload the boiler from the skid.

  • Page 11: Placement Of Boiler

    Preinstallation Vitocrossal 200 CI2 Installation Placement of Boiler Positioning boiler Without seismic feet The boiler must be placed on a load bearing foundation. This allows for the connection of a neutralization system. 750 1000 1500 2000 Model 1040 1200 1000 1000 1000 1000...

  • Page 12: Lan Connection

    Preinstallation Vitocrossal 200 CI2 Installation WiFi Operational Reliability and System Requirements (continued) Angle of penetration Flat (unfavourable) angle of penetration The reception quality remains best if wireless signals hit the walls vertically. Depending on the angle of penetration, the effective wall thickness changes and so does the extent to which the electromagnetic waves are damped.

  • Page 13: Boiler Connections

    Installation Vitocrossal 200 CI2 Installation Boiler Connections Note: To provide a better overview, the boiler is shown here without its jacketing. Boiler model CI2 Pos. Connection 1000 1500 2000 Boiler supply NPT 2 in. NPT 2 in. 2.5 in. 2.5 in. 4 in.
  • Page 14 Note: Piping diagrams for specific system layouts are available. Please enquire with your local Viessmann sales representative. All Vitocrossal 200 boilers are hydrostatically factory tested to ASME requirements.
  • Page 15 B Air vent with shut-off base on operating pressure requirements. Contact your local C Street elbow c in. Viessmann sales representative for details. D Reducing elbow 1a in. to 1 in. E Nipple 1 in. F Pressure relief valve, 80 psi *2...

  • Page 16: Gas Connections

    Installation Vitocrossal 200 CI2 Installation Gas Connections CI2 1500 Vitocrossal 200 CI2 1500 Legend 1 Burner section 1, lead (500 MBH) 2 Burner section 2, lag (1000 MBH) A Field supplied and installed gas shut-off valve B Field supplied and installed union C Field supplied and installed service gas pressure regulator (required for all installations) D Field supplied and installed union...
  • Page 17 Installation Vitocrossal 200 CI2 Installation Gas Connections (continued) The gas train on the burner meets the requirements of ASME/CSD-1. 1. Connect gas pipe A to the gas valve. Gas connection: Vitocrossal 200, CI2: 1b in. NPT for models 399, 500, 750 and 1000, 2 in.
  • Page 18 Installation Vitocrossal 200 CI2 Installation Gas Connections (continued) 1. Refer to current CAN/CSA B149.1 and .2 or National Fuel Gas Code ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing. Pipe size to the boiler must be determined based on: - pipe length - number of fittings - type of gas...

  • Page 19: Electrical Connections

    Installation Vitocrossal 200 CI2 Installation Electrical Connections To access the BCU and control unit, panels have to be CI2 399 to 1000 removed. 1. Turn the power switch off and disconnect the power supply to the boiler, close gas shutoff valve. 2.
  • Page 20 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) CI2 399 to 1000 CAUTION Melting insulation can lead to equipment damage. Electronic wires must not come into contact with each other or hot components. 1. Remove two screws for junction box access door. 2.
  • Page 21 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Location of the control unit components for CI2 399 to 1000 Rear of the boiler Front of the boiler Legend Legend B Control unit with WP and MZIO A BCU C LAN socket D DIN rail Location of the control unit components for CI2 1500/2000 Rear of the boiler...
  • Page 22 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Overview of connections to the wiring panel and MZIO Note: For further information on the connections, see the following chapters. Wiring panel MZIO fÖ Power cable DIN rail Zone 1, pump P1 Output 120V for: Zone 2, pump Zone 3, pump DHW pump downstream of low loss header...
  • Page 23 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Connecting the ventilation air supply to the CAI plug External blocking via switching contact Connection options: A motorized ventilation air supply (e.g. fan or ventilation Digital input DIS at the MZIO air damper) with or without feedback signal can be connected to the CAI plug (see page 22).
  • Page 24 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Outside temperature sensor ! Fitting location for outside temperature sensor Connecting the tank temperature sensor % or tank with temperature switch (ie Aquastat) North or north-westerly wall, 6 to 8 ft. (2 to 2.5 m) ...
  • Page 25 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Pump connection WP/MZIO 120V~ Specification of the pump 120V~ Rated current: >2A Specification of the contactor: Rated voltage: 120V Rated current: 1A Legend A Pump B Contactor/Relay C Power supply with disconnect and protection D Pump signal connection Pump connection WP/MZIO 240V~ Specification of the pump 240V~...
  • Page 26 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Checking the CAN bus terminator switch setting The CAN bus resistor is switched using switch A in the wiring chamber. Connecting a cascade via CAN bus Connect 2 cables of the previous and following heat generator to plug lA: Legend Loosen the screws in the terminals.
  • Page 27 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Accessories with direct power supply Connecting PlusBus subscribers Notes on connecting PlusBus subscribers As a maximum, the following PlusBus subscribers can be connected to the control unit: 3 EM-M1 extension (ADIO electronics module) 2 Vitotrol 200-E 3 EM-EA1 extensions (DIO electronics module) 1 EM-P1 extension (ADIO electronics module)
  • Page 28 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Subscriber numbers of connected extensions All extensions connected to the boiler must have a subscriber number. The subscriber number is set on rotary switch S1 at each extension. Rotary switch S1 settings: EM-EA1 extension (max.
  • Page 29 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Overview of terminal block connections DIN rail CI2 399 to 1000 DIN rail CI2 1500/2000 Legend A Low water cut-off power supply B Low water cut-off feedback C Flue gas damper for common venting feedback (factory installed jumper) D Flue gas damper for common venting power supply Boiler isolation valve (power open spring return)
  • Page 30 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Note: The DIN terminals can be used with solid, stranded or stranded with ferrule termination. The ferrule will help to prevent ‘fraying’ of the stranded wires during installation. Specific connections are detailed throughout the manual, refer to the appropriate section prior to making any connections.
  • Page 31 Rated current Max. Note: Boiler isolation valve must be power open spring return. Boiler isolation valves are available from Viessmann as an accessory. 2 in. isolation valve (CI2 399/500) Part number 7946553 2b in. isolation valve (CI2 750/1000) Part number 7946552 4 in.
  • Page 32 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Pump connection 120V~ Specification of the pump 120V~ Rated current: >2A Specification of the contactor: Rated voltage: 120V Rated current: 1A Legend A DIN rail (located in the junction box) B Contactor/relay (field supplied) C Pump D Power supply w/disconnect and protection Pump connection 240V~...
  • Page 33 Installation Vitocrossal 200 CI2 Installation Electrical Connections (continued) Connection of Low Water Cut-off Device CAUTION Note: The boiler is supplied with a LWCO wiring harness. The diagram shown is only a simplified conceptual 1. Make connection for (LWCO) switching contact at drawing of a typical low water cut off (LWCO) device.

  • Page 34: Boiler Power Supply

    Installation Vitocrossal 200 CI2 Installation Boiler Power Supply CI2 399 to 1000 CI2 1500 and 2000 WARNING IMPORTANT The control must be grounded. Electrical installations must comply with the latest edition of: Ensure that ‘L’, ‘N’ and ‘G’ are not interchanged. In the U.S.A., the National Electrical Code (NEC), ANSI/NFPA 70 and any other state, local codes and/or regulations.

  • Page 35: Connections On The Flue Gas Side

    Installation Vitocrossal 200 CI2 Installation Connections on the Flue Gas Side CI2 399 to 1000 Fitting the condensate trap Note: The condensate trap is included with the boiler. 1. Fit the condensate trap. 2. Check that the condensate can drain freely. WARNING Escaping flue gas can cause life threatening poisoning from carbon monoxide.

  • Page 36: Condensate Connection

    Installation Vitocrossal 200 CI2 Installation Condensate Connection The Vitocrossal 200, CI2 boiler is supplied with a condensate trap (field installed). An external trap is not required when connecting the field drain to the P-trap. Discharge tubing (field supplied) must be 1 in. diameter. Use CPVC, PVC or other material approved by code listed below.

  • Page 37: Connections On The Flue Gas Side

    Installation Vitocrossal 200 CI2 Installation Connections on the Flue Gas Side Connecting the neutralizing system (accessories) The condensate trap is equipped with a float. If Note: there is no water in the condensate trap, the float closes it. The drain F must be lower than the condensate trap. Ensure there is an air gap around the condensate hose E at the drain F to allow the condensate to flow freely.

  • Page 38: Initial System Fill General Requirements

    Installation Vitocrossal 200 CI2 Installation Initial System Fill General Requirements Treatment of boiler feed water should be considered in The pressure relief valve must be attached to the top areas of known problems, such as high mineral content of the boiler or the safety supply of the boiler (see page and hardness.

  • Page 39: General

    They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local If a DHW storage tank other than a Viessmann Vitocell Viessmann sales representative office. 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank.

  • Page 40: System Layout 1

    System Layout Vitocrossal 200 CI2 Installation System Layout 1 itocrossal 200, CI2 with... - DHW storage tank - 3 zone circuits - 3 heating circuits with a mixing valve Installation of different heating circuits... Legend Vitocrossal 200, CI2 boiler 3 zone circuits (radiator heating circuit) ■...

  • Page 41: System Layout 2

    System Layout Vitocrossal 200 CI2 Installation System Layout 2 itocrossal 200, CI2 with... - DHW storage tank - 3 zone circuits - 3 heating circuits with a mixing valve Installation of different heating circuits... Legend Vitocrossal 200, CI2 boiler 3 zone circuits (radiator heating circuit) ■...

  • Page 42: System Layout 3

    WARNING If a DHW storage tank other than a Viessmann Vitocell 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank.

  • Page 43: System Layout 4

    Each boiler in a cascade system must be able to be individually isolated from the heating system through the use If a DHW storage tank other than a Viessmann Vitocell of boiler isolation valves. 300 tank is used, the installer must verify proper operation of the Viessmann DHW tank temperature sensor with the original manufacturer of the tank.

  • Page 44: Boiler Piping In Heating/Cooling Application

    System Layout Vitocrossal 200 CI2 Installation Boiler Piping in Heating/Cooling Application The Vitocrossal 200, CI2 boiler, when used in connection Heating / with a refrigeration system, must be installed so that the Cooling unit chilled medium is piped in parallel to the boiler and with appropriate valves to prevent the chilled medium from Heating / Cooling unit...

  • Page 45: Connections On The Flue Gas Side

    Venting Vitocrossal 200 CI2 Installation Connections on the Flue Gas Side Note: Connect the flue outlet with the shortest possible run Vitocrossal 200 CI2 399 to 1000 to the flue pipe. Avoid sharp bends. Note: Motorized flue gas damper available as an accessory, for common vented systems.
  • Page 46 Venting Vitocrossal 200 CI2 Installation Connections on the Flue Gas Side (continued) IMPORTANT Connect flue gas collector with the flue gas pipe using the shortest possible route. Avoid sharp bends. Internal diameter boiler-flue collar 1000 1500 2000 Model 104.2 205.2 1.

  • Page 47: General Venting Information

    Venting Vitocrossal 200 CI2 Installation General Venting Information Installation steps (outline) Route vent pipe as directly as possible and with as few WARNING bends as possible to the boiler. Check proper location of gaskets in rigid PP(s) pipe collars. Ensure that the entire venting system is protected from (Only use supplied parts with the polypropylene venting physical damages.
  • Page 48 Venting Vitocrossal 200 CI2 Installation General Venting Information (continued) Combustion air intake materials Part Material Certified to Standards Applicability Combustion air intake pipe Stainless steel No applicable standards U.S.A./Canada and fitting Galvanized steel Suitable for outdoor use PVC-DWV ANSI/ASTM D2661 Schedule 40 CSA B181.1 ULC S102.2...
  • Page 49 Venting Vitocrossal 200 CI2 Installation General Venting Information (continued) Vent termination location requirements (for installations in Canada) The vent must be installed observing local regulations in 8..underneath a veranda, porch or deck, unless: addition to National Codes, CAN/CSA-B149.1 or 2. The the veranda, porch, or deck is fully open on a minimum flexible vent pipe can only be used in vertical installations.

  • Page 50: Connecting Combustion Air Intake For Direct Vent

    (formerly Exhausto) For sealed combustion systems that are vertically vented, www.securitychimneys.com www.enervex.com a Viessmann vacuum relief damper may be needed to protect the vent system against vacuum conditions. Jeremias Inc. Van-Packer Co. Inc. This very rare occurrence can happen when a boiler is www.jeremiasinc.com...

  • Page 51: Requirement For Rigid Ss/Pp(S)/Cpvc Vent Pipe Material

    Fuel Gas Code ANSI Z223.1 or NFPA Standard 54. different vent system manufacturers. To ensure safe operation of the appliance, Viessmann Refer to the vent length requirements on page 56 for recommends that the system be inspected once a year two pipe vent installations and page 60 for single pipe by a qualified service technician.

  • Page 52: Adaptor Chart

    ISSA0808 PolyPro FSA-04M-4PPF FSA-06M-6PPF FSA-08M-8PPF Z-Flex 2ZDZV4 2ZDZV6 2ZDZV8 CPVC Viessmann PN 7975564 7975565 7975566 Legend A Adaptor B Flue collar clamp C Boiler flue outlet Vent Requirements The boiler must be vented and supplied with combustion Combustion air supply, room air dependent application only air and exhaust vents as described in this section.

  • Page 53: Direct Venting (Two Pipe System)

    Venting Vitocrossal 200 CI2 Installation Direct Venting (Two Pipe System) Side wall vent termination [stainless steel, CPVC or PP(s)] Stainless steel or plastic mesh IMPORTANT Min. 36 in. The exhaust vent/air intake system must terminate so that (915 mm) proper clearances are maintained as cited in local codes or the latest edition of the “Natural Gas and Propane Installation Code”...

  • Page 54: Side Wall Venting

    Venting Vitocrossal 200 CI2 Installation Side Wall Venting Side wall vent termination [stainless steel, CPVC or PP(s)] IMPORTANT For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer). Min.

  • Page 55: Vent Termination Location Requirements - Vertical

    Venting Vitocrossal 200 CI2 Installation Vent Termination Location Requirements - Vertical The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2 (for installations in Canada) or ANSI-Z223.1 or NFPA 54 (for installations in the U.S.A.). WARNING Vent termination must be at least 12 in.

  • Page 56: Two Pipe System - Vertical Exhaust/Vertical Air Intake

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Two Pipe System - Vertical Exhaust/Vertical Air Intake Flue a - Equivalent exhaust length b - Equivalent air intake length Vertical intake and exhaust Vitocrossal 200 CI2 Boiler model 1000 1500 2000 Boiler flue collar (internal diameter) in.
  • Page 57 Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Two Pipe System - Vertical Exhaust/Vertical Air Intake IMPORTANT All PP(s) vent termination elbows, must be secured in place as specified by manufacturer. IMPORTANT For PP(s) systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).

  • Page 58: Two Pipe System - Horizontal Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Two Pipe System - Horizontal Exhaust/Horizontal Air Intake Min. 36 in. (915 mm) Flue a - Equivalent exhaust length b - Equivalent air intake length Vertical intake and exhaust Vitocrossal 200 CI2 Boiler model 1000 1500 2000...

  • Page 59: Two Pipe System - Vertical Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Two Pipe System - Vertical Exhaust/Horizontal Air Intake Flue a - Equivalent exhaust length b - Equivalent air intake length Vertical intake and exhaust Vitocrossal 200 CI2 Boiler model 1000 1500 2000 Boiler flue collar (internal diameter) in.

  • Page 60: Single Pipe System - Vertical Exhaust/Room Air Dependant

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Single Pipe System - Vertical Exhaust/Room Air Dependant Flue Room Combustion Air Opening a - Equivalent exhaust length Vertical intake and exhaust Vitocrossal 200 CI2 Boiler model 1000 1500 2000 Boiler flue collar (internal diameter) in.

  • Page 61: Single Pipe System - Horizontal Exhaust/Room Air Dependant

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Single Pipe System - Horizontal Exhaust/Room Air Dependant Room Combustion Air Opening Flue a - Equivalent exhaust length Vertical intake and exhaust Vitocrossal 200 CI2 Boiler model 1000 1500 2000 Boiler flue collar (internal diameter) in.

  • Page 62: Multiple Boiler Installations

    Venting Options - Stainless Steel/PP(s)/CPVC Vitocrossal 200 CI2 Installation Multiple Boiler Installations Horizontal vent termination 36 in. min. (915 mm min.) Note: 36 in. (915 mm) minimum distance apart for horizontal vent terminations. Vertical vent termination 6 in. min. (150 mm min.) 4 in.

  • Page 63: Lighting And Operating Instructions

    Additional Information Vitocrossal 200 CI2 Installation Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 64 Vitocrossal 200 CI2 Installation Scan for digital copy of this document...

This manual is also suitable for:

Vitocrossal 200Vitocrossal 200 ci2 399Vitocrossal 200 ci2 500Vitocrossal 200 ci2 750Vitocrossal 200 ci2 1000Vitocrossal 200 ci2 1500 ... Show all

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