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Viessmann Vitocrossal 200 Installation Instructions Manual

Cm2 series 400, 500 and 620 gas condensing boiler with cylinder burner, heating input: 1445 to 2245 mbh (423 to 658 kw)
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See also: Instruction Manual , Technical Data Manual
Installation Instructions
for use by heating contractor
Vitocrossal 200
CM2 Series 400, 500 and 620
Gas condensing boiler with cylinder burner
Heating input:
1445 to 2245 MBH
(423 to 658 kW)
VITOCROSSAL 200
H
5773 597 - 04 09/2014
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

  • Page 1 Installation Instructions for use by heating contractor Vitocrossal 200 CM2 Series 400, 500 and 620 Gas condensing boiler with cylinder burner Heating input: 1445 to 2245 MBH (423 to 658 kW) VITOCROSSAL 200 Product may not be exactly as shown...

  • Page 2: Safety, Installation And Warranty Requirements

    Safety Vitocrossal 200, CM2 400, 500 and 620 Installation Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.

  • Page 3: Fiberglass Wool And Ceramic Fiber Material

    Safety Vitocrossal 200, CM2 400, 500 and 620 Installation Safety, Installation and Warranty Requirements Fiberglass wool and ceramic fiber materials First aid measures - If eye contact occurs, flush eyes with water to WARNING remove dust. If symptoms persist, seek medical attention.

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 200, CM2 400, 500 and 620 Installation Page Introduction Safety, Installation and Warranty Requirements....2 Product documentation..........2 Warranty..............2 Licensed professional heating contractor.....2 Contaminated air.............2 Advice to owner............2 Carbon monoxide.............2 Fresh air..............2 Equipment venting...........2 Fiberglass wool and ceramic fiber material....3 First aid measures............3...
  • Page 5 Table of Contents Vitocrossal 200, CM2 400, 500 and 620 Installation Page Venting General Venting Information........34 Installation steps (outline)........34 Recommended venting practice.......34 Approved venting materials........35 Vent termination location requirements (for installations in Canada)........36 Vent termination location requirements (for installations in the U.S.A.)........36 Flashing and storm collar installation......37...

  • Page 6: Important Regulatory And Installation Requirements

    General Information Vitocrossal 200, CM2 400, 500 and 620 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...

  • Page 7: For Polypropylene Venting Systems Only

    General Information Vitocrossal 200, CM2 400, 500 and 620 Installation Important Regulatory and Installation Requirements (continued) For Polypropylene venting systems only Working on the equipment Minimum and maximum wall thickness through which the The installation, adjustment, service, and maintenance of...

  • Page 8: About These Installation Instructions

    For operation with modulating boiler water temperatures must be compatible with the connected radiation. in closed loop, forced circulation hot water heating The Vitocrossal 200 boiler is suitable for a maximum systems. operating pressure of 75 psig and a maximum boiler The Vitocrossal 200, CM2 boilers are CSA certified with water temperature of 210°...

  • Page 9: Mechanical Room

    Do not use exhaust fans without adding additional provisions for fresh combustion air (e.g. fresh air fan) in the boiler room and do not install the Vitocrossal 200 boiler in rooms with refrigeration equipment. This boiler requires uncontaminated air for safe operation - do not install where chemicals are stored.

  • Page 10: Boiler

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Recommended Minimum Service Clearances To enable convenient installation and maintenance, observe the stated clearance dimensions. Maintain the minimum clearances where space is tight. In the delivered condition, the boiler door hinge bracket is factory installed on the left side of the door.

  • Page 11: Preparing The Boiler

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Preparing the Boiler Note: To install lifting straps, use the lifting holes in the boiler end plates B. Observe the minimum clearances, see page 10. It is recommended that the boiler is to be installed on a concrete base.

  • Page 12: Boiler Insulation

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler Insulation Remove all the components of the boiler jacket from the shipping box. 1. Wrap around the insulation blanket A (black nylon facing out) and look for boiler’s fitting cutouts.

  • Page 13: Boiler Door

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler Door (continued) Converting the boiler door 1. To convert the boiler door to the opposite side move hinge pin A to the RH side. Note: Ensure that sealing frame B presses onto the centre of gasket D in the boiler opening.

  • Page 14: Combustion Air Flex Hose

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Combustion Air Flex Hose 1. Attach the flex hose 8 in. (200 mm) to the flex hose adaptor and secure the flex hose to the flex hose adaptor with the retaining clamp.

  • Page 15: Boiler Connections

    Note: Piping diagrams for specific system layouts are available. Please enquire with your local Viessmann sales representative. IMPORTANT The Vitocrossal 200 is only suited for hot water heating. Do not install a 4-way mixing valve, bypass valve or similar.

  • Page 16: Safety Header

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler Connections (continued) Legend 1 Boiler return: (ANSI 4 in.)* 2 Boiler supply: (ANSI 4 in.)* 3 Safety port (Safety valve, low water cutoff and Safety Header automatic air vent) NPT 1a CAUTION A Cross 1a in.

  • Page 17: Hydrostatic Test Procedure

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Hydrostatic Test Procedure All Vitocrossal boilers are factory tested (hydrostatic testing) to ASME requirements. The following testing procedure is to ensure that the boiler remained intact during shipping and handling. 1. Isolate boiler from hydronic heating system using isolating valves (i.e.

  • Page 18: Rails And Supports

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Rails and Supports 1. Insert four M6 x 10 screws halfway into each side of the top and base frame. 2. Hook the top LH and RH rails onto the top frame using the keyholes.

  • Page 19: Cross Bar

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Cross Bar 1. Install the cross bar (using the rear holes) to the top rail with two screws. Mounting the Burner 1. Insert six M12 threaded studs into the boiler door.

  • Page 20: Combustion Air Adapter Burner Connection

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Combustion Air Adapter Burner Connection 1. Secure intake connector with hex head screws, washers and nuts to the flange of the rotary damper. 2. Secure ventilation air hose DN 200 with hose clip 200 mm) on the intake connector.

  • Page 21: Front Side Panels

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Front Side Panels The gas train on the burner meets the requirement of ASME/CSD-1. 1. Cut out the aperture in front side panel either left or right. Note: For ease during burner maintenance, route the gas...

  • Page 22: Electrical Connections

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Electrical Connections Note: Never allow cables or leads to come into contact with hot components. Secure all cables and leads with cable ties. 1. Route the burner cables to the burner; apply strain reliefs or cable connectors as required.

  • Page 23: Routing Cables

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Routing Cables 3A 3B Boiler water temperature sensor (supplied with Note: Route 120V cables F and low voltage leads the control unit) For installation see page 25. separately. 15 Flue gas temperature sensor...

  • Page 24: Boiler Water Temperature Sensor

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler Water Temperature Sensor Note: The boiler water temperature sensor is located at the boiler supply connection. 1. Remove spring clip (set aside). 2. Insert 6 in. (150 mm) temperature sensor.

  • Page 25: Condensate Connection

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Condensate Connection 1. Fill the siphon with water and attach to boiler. IMPORTANT The condensate drain must be able to be inspected. Legend A Condensate drain...
  • Page 26 The amount of condensate to be expected during the operation of the boiler and can be read from the chart. If the condensate outlet of the Vitocrossal 200 boiler is lower than the drain, a condensate pump must be Boiler water return temperature installed.

  • Page 27: Rear Panels

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Rear Panels 1. Install rear lower panel and secure with screws. 2. Install rear upper panel and secure with screws. 3. Install rear middle panel and secure with screws. Note: The gap in the middle rear panel is for inspection of the flue gas temperature sensor.

  • Page 28: Top Panels

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Top Panels Top Panels 1. Secure the front edge of central top panel A to the tie-bar with two 4.8 mm screws and secure the back of the panel to the LH and RH top rails with one 4.8 mm screw each.

  • Page 29: Control Panel And Covers

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Control Panel and Covers 1. Plug in control interface cable and install cover. 2. Install control cosmetic cover. 3. Install buffer panel to the top rail and secure with 4.8 mm metal screws.

  • Page 30: Gas Connections

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Gas Connections The gas line on the burner meets the requirements of ASME/CSD-1. Note: For ease during burner maintenance, route the gas supply pipe from the opposite side of the burner hinges (otherwise the panel cannot be removed when swinging burner left or right).

  • Page 31: Valve Leak Test

    Boiler Vitocrossal 200, CM2 400, 500 and 620 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:...

  • Page 32: Boiler Piping In Heating / Cooling Application

    Boiler Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler Piping in Heating / Cooling Application The boiler, when used in connection with a refrigeration Heating / system, must be installed so that the chilled medium is Cooling unit piped in parallel to the boiler and with appropriate valves to prevent the chilled medium from entering the boiler.

  • Page 33: Initial System Fill

    Unsuitable water quality may damage boiler. The Vitocrossal 200 boiler is only suitable for closed hot water heating systems with pumps. It is strongly recommended to install boiler isolation valves and above these isolation valves, drain valves in the system supply and return.

  • Page 34: Venting

    Venting Vitocrossal 200, CM2 400, 500 and 620 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 pipe collars.

  • Page 35: Approved Venting Materials

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation General Venting Information (continued) Approved venting materials Part Material Certified to Standards Applicability Exhaust pipe and fittings Stainless steel UL1738 U.S.A./Canada “Venting systems for gas-burning appliances, Categories II, III, IV” ULC S636 “Standard for Type BH gas venting...

  • Page 36: Vent Termination Location Requirements (For Installations In Canada)

    Venting Vitocrossal 200, CM2 400, 500 and 620 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 ...

  • Page 37: Flashing And Storm Collar Installation

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation General Venting Information (continued) Flashing and storm collar installation Flashings and storm collars are field supplied. Flashings and storm collars suitable for Type B vent materials (or better) may be used.

  • Page 38: Vent Pipe Material

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Requirement for UL/ULC Listed Rigid SS/PP(s) Vent Pipe Material Requirements for PP and stainless steel The venting system must be installed by a licensed IMPORTANT professional heating contractor familiar with the operation and maintenance of heating appliances and venting.

  • Page 39: Vent Requirements

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Vent Requirements Combustion air supply, room air dependent application only This boiler requires fresh air for safe operation and If boiler is installed in a confined space (a space with a...

  • Page 40: Direct Venting (Two Pipe System)

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Direct Venting (Two Pipe System) Side wall vent termination [stainless steel, CPVC or PP] IMPORTANT Stainless steel or The exhaust vent/air intake system must terminate so plastic mesh that proper clearances are maintained as cited in local codes or the latest edition of the “Natural Gas and...

  • Page 41: Side Wall Venting

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Side Wall Venting Side wall vent termination [stainless steel or PP] IMPORTANT For PP systems, all exhaust vent and air intake piping and elbows exposed outside, must be UV resistant polypropylene (supplied by the vent manufacturer).

  • Page 42: Component Installation Guide

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Component Installation Guide Flashing and storm collar installation Flashings and storm collars are field supplied. Flashings and storm collars suitable for Type B vent materials (or better) may be used. To obtain flashings and storm collars, please contact your local vent material supplier.

  • Page 43: Installation Of Support System - Pp

    Venting Vitocrossal 200, CM2 400, 500 and 620 Installation Installation of Support System - PP Bracing Contact your local vent material supplier for more IMPORTANT information specific to your installation. Braces are required to stabilize an installation. There are different For exhaust vent pipe material: types and their use and spacing vary.

  • Page 44: Venting Options - Stainless Steel/Pp

    Venting Options - Stainless Steel / PP Vitocrossal 200, CM2 400, 500 and 620 Installation Two Pipe System - Vertical Exhaust / Vertical Air Intake Flue a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table on page 47.

  • Page 45: Two Pipe System-Vertical/Horizontal Installations

    Vitocrossal 200, CM2 400, 500 and 620 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 46: Single Pipe-Vertical Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200, CM2 400, 500 and 620 Installation Two Pipe System - Horizontal Exhaust / Horizontal Air Intake Flue Min. 24 in. (610 mm) a - Equivalent length (exhaust) b - Equivalent length (air intake)

  • Page 47: Two Pipe System-Vertical Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200, CM2 400, 500 and 620 Installation Two Pipe System - Vertical Exhaust / Horizontal Air Intake Flue a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table below.
  • Page 48 Venting Options - Stainless Steel / PP Vitocrossal 200, CM2 400, 500 and 620 Installation Single Pipe System - Vertical Exhaust / Room Air Dependant Flue Combustion Air Opening a - Equivalent length (exhaust) Note: See table on page 49.
  • Page 49 Venting Options - Stainless Steel / PP Vitocrossal 200, CM2 400, 500 and 620 Installation Single Pipe System - Vertical / Horizontal Installations Maximum allowable equivalent length - Stainless steel / PP Boiler Models CM2 400, 500 and 620 Flue gas in.
  • Page 50 Vitocrossal 200, CM2 400, 500 and 620 Installation...

This manual is also suitable for:

Cm2 400Vitocrossal 500Vitocrossal 620Cm2 500Cm2 620

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