Viessmann Vitocrossal 200 CM2 Series Installation Instructions Manual
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Viessmann Vitocrossal 200 CM2 Series Installation Instructions Manual

Viessmann Vitocrossal 200 CM2 Series Installation Instructions Manual

Gas condensing boiler with cylinder burner heating input: 663 to 1112 mbh 194 to 326 kw
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Download this manual See also: Technical Manual
Installation Instructions
for use by heating contractor
Vitocrossal 200
CM2 Series
Gas condensing boiler with cylinder burner
Heating input:
663 to 1112 MBH
194 to 326 kW
VITOCROSSAL 200
H
5607 705 - 05 10/2014
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 CM2 Series

  • Page 1 Installation Instructions for use by heating contractor Vitocrossal 200 CM2 Series Gas condensing boiler with cylinder burner Heating input: 663 to 1112 MBH 194 to 326 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

     to installation of carbon monoxide detectors. Once the installation work is complete, the heating Follow the Viessmann maintenance schedule of the contractor must familiarize the system operator/ boiler in the “Service Instructions” manual. ultimate owner with all equipment, as well as safety...

  • Page 3: Table Of Contents

    Table of Contents Vitocrossal 200 CM2 Installation Instructions 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 Safety Important Regulatory and Installation Requirements..5 Fiberglass wool and ceramic fiber material....5 First aid measures............5 Codes..............5 Mechanical room.............5...
  • Page 4 Table of Contents Vitocrossal 200 CM2 Installation Instructions Page Venting General Venting Information........29 Installation steps (outline)........29 Recommended Venting Practice........29 Approved venting materials........30 Vent termination location requirements (for installations in Canada)........31 Vent termination location requirements (for installations in the U.S.A.)........31 Flashing and storm collar installation......32 Additional Requirements for Stainless Steel Vent Pipe Material.............32 Exhaust vent/air intake connection to boiler....32...

  • Page 5: Safety

    9 in this manual. - Operations such as sawing, blowing, tear-out and spraying may generate airborne fiber concentration Viessmann recommends installation of an additional requiring additional protection. electrical disconnect switch and a fuel shut-off valve (if possible) outside the mechanical room or enclosed area of installation.

  • Page 6: For Installations On The Commonwealth Of Massachusetts

    Safety Vitocrossal 200 CM2 Installation Instructions Important Regulatory and Installation Requirements (continued) 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 7: For Polypropylene Venting Systems Only

    Safety Vitocrossal 200 CM2 Installation Instructions Important Regulatory and Installation Requirements (continued) For Polypropylene venting systems only Minimum and maximum wall thickness through which the WARNING horizontal vent-air intake termination may be installed: Minimum: 1 in. (25.4 mm) The Vitocrossal 200 is NOT approved for common Maximum: 30 in.

  • Page 8: Working On The Equipment

    Literature for the Vitocrossal 200 CM2 boiler: Leave all literature at the installation site and advise the system operator/ultimate owner where the - Technical Data Manual literature can be found. Contact Viessmann for - Installation Instructions additional copies. - Service Instructions - Operating Instruction This product comes with several safety instruction...

  • Page 9: Product Information

    The Vitocrossal 200, CM2 boilers are CSA certified with Viessmann burners which must be used in conjunction with this boiler series. The proper burner size must be verified and the burner must be adjusted so that the maximum input of the appropriate boiler size is always observed and adjusted.

  • Page 10: Boiler

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

  • Page 11: Preparing The Boiler

    Boiler Vitocrossal 200 CM2 Installation Instructions Preparing the Boiler Note: To install cargo gear, use the gaps in the boiler frame 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

    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.

  • Page 13: Safety Header

    Boiler Vitocrossal 200 CM2 Installation Instructions Boiler Connections (continued) Legend 1 Boiler return: (ANSI flanges 2b in.) *1 Safety Header 2 Boiler supply: (ANSI flanges 2b in.)*1 CAUTION 3 Safety port (Safety valve, low water cutoff and automatic air vent) NPT 1a Do not connect heating system to safety header.

  • Page 14: Hydrostatic Test Procedure

    Boiler Vitocrossal 200 CM2 Installation Instructions 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 15: Burner Installation

    Boiler Vitocrossal 200 CM2 Installation Instructions Burner Installation 1. Remove burner from shipping package and align with boiler opening. Note: All parts needed for burner installation are included in the burner shipping package. 2. Hang the burner on the hinges bracket. Note: The burner hinge bracket can be reinstalled on the other side of the door if required.

  • Page 16: Rails And Front Panels

    Boiler Vitocrossal 200 CM2 Installation Instructions Rails and Front Panels 1. Install mounting rails to bottom of boiler frame using M6 x 10 screws. 2. Install mounting rails to top of boiler frame using M6 x 10 screws. 3. Install bottom panel to front of boiler frame using M6 screws.

  • Page 17: Combustion Air Adapter Burner Connection

    Boiler Vitocrossal 200 CM2 Installation Instructions Combustion Air Adapter Burner Connection For CM2 boiler model 186 only 1. Install the combustion air intake adaptor to the burner air inlet using four M6 x 20 bolts, nuts and washers Connect the combustion air flex hose to the burner flange adaptor and secure with retaining clamp.

  • Page 18: Side Panels

    Boiler Vitocrossal 200 CM2 Installation Instructions Side Panels Note: Adjust the side panels to line up with the front panel A before securing with screws. 1. Install rear right side panel. Observe aligning notches and cutouts. 2. Secure rear right panel to top rail with two 4.8 metal screws.

  • Page 19: Flue Gas Temperature Switch

    Boiler Vitocrossal 200 CM2 Installation Instructions Flue Gas Temperature Switch Flue temperature switch During the operation of the boiler, should the switch Boilers with a polypropylene flue gas collector are supplied become activated (open as a safety cut-out), check the with a flue gas temperature switch, which must be installed.

  • Page 20: Rear Panels

    Boiler Vitocrossal 200 CM2 Installation Instructions 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 21: Gas Flue Temperature Switch Connection

    Boiler Vitocrossal 200 CM2 Installation Instructions Flue Gas Temperature Switch Connection Refer to the Vitotronic Installation and Service Instructions for details. Sensors and Buffer Panel The boiler water temperature sensor B is included in control’s shipping package. Plug 40 is plugged into control.

  • Page 22: Top Panels

    Boiler Vitocrossal 200 CM2 Installation Instructions Top Panels 1. Install top left panel. 2. Install top right panel. 3. Secure the rear of both panels with metal screws. 4. Secure the front of both panels with metal screws. 5. Install top panel of the junction box. 6.

  • Page 23: Condensate Connection

    Boiler Vitocrossal 200 CM2 Installation Instructions Condensate Connection The Vitocrossal CM2 boiler comes with a built-in 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 24: Gas Connections

    Boiler Vitocrossal 200 CM2 Installation Instructions Gas Connections 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 supply pipe from the opposite side of the burner hinges (otherwise the panel cannot be removed when swinging burner left or right).

  • Page 25: Valve Leak Test

    Boiler Vitocrossal 200 CM2 Installation Instructions 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 26: Burner Electrical Connections

    Boiler Vitocrossal 200 CM2 Installation Instructions Gas Connections (continued) Burner swing left or right 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). Legend A Gas pipe B Right front side panel...

  • Page 27: Front Panel (Door)

    Boiler Vitocrossal 200 CM2 Installation Instructions Front Panel (door) 1. Screw profile studs into the threads of the front panel (door). 2. Insert front panel retainers into the notches on the bottom panel. 3. Tilt up the door and snap door into place. 4.

  • Page 28: Initial System Fill

    Boiler Vitocrossal 200 CM2 Installation Instructions Initial System Fill Treatment of boiler feed water should be considered in The pressure relief valve must be attached to the top of areas of known problems, such as high mineral content the boiler or the safety supply of the boiler, see page 13. and hardness.

  • Page 29: Venting

    Venting Vitocrossal 200 CM2 Installation Instructions 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. Ensure that the entire venting system is protected from ...

  • Page 30: Approved Venting Materials

    Venting Vitocrossal 200 CM2 Installation Instructions 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 systems”...

  • Page 31: Vent Termination Location Requirements (For Installations In Canada)

    Venting Vitocrossal 200 CM2 Installation Instructions 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 32: Flashing And Storm Collar Installation

    Venting Vitocrossal 200 CM2 Installation Instructions 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. To obtain flashings and storm collars, please contact your local vent material supplier.

  • Page 33: Vent Pipe Material

    DO NOT mix pipe, fittings, or joining methods from National Fuel Gas Code ANSI Z223.1 or NFPA Standard 54. different vent system manufacturers. To ensure safe operation of the appliance, Viessmann recommends that the system be inspected once a year The vent length requirements stated in this manual (on page 39 for two pipe vent installations and page by a qualified service technician.

  • Page 34: Vent Requirements

    Venting Vitocrossal 200 CM2 Installation Instructions 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 must be installed in a mechanical room where there are volume of less than 50 cubic feet per 1000 Btu/h of gas provisions for adequate combustion and ventilation air.

  • Page 35: Direct Venting (Two Pipe System)

    Venting Vitocrossal 200 CM2 Installation Instructions 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 Propane Installation Code”...

  • Page 36: Side Wall Venting

    Venting Vitocrossal 200 CM2 Installation Instructions 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). Min.

  • Page 37: Component Installation Guide

    Venting Vitocrossal 200 CM2 Installation Instructions 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 38: Installation Of Support System - Pp

    Venting Vitocrossal 200 CM2 Installation Instructions 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 39: Venting Options - Stainless Steel/Pp

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Vertical Exhaust / Vertical Air Intake Flue a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table on page 40.
  • Page 40 Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Vertical Exhaust / Vertical Air Intake (continued) 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 41: Two Pipe System-Horizontal Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Horizontal Exhaust / Horizontal Air Intake Flue Min. 24 in. (610 mm) a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table on page 42.

  • Page 42: Two Pipe System-Vertical Exhaust/Horizontal Air Intake

    6 (150) 10 (250) 6 (150) 12 (300) Max. equivalent length Contact Viessmann for vent length calculation a+b [ft. (m)] 200 (60) Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25%...

  • Page 43: Single Pipe System-Vertical Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Single Pipe System - Vertical Exhaust / Room Air Dependant Flue Combustion Air Opening a - Equivalent length (exhaust) Note: See table on page 45. Single Pipe System - Horizontal Exhaust / Room Air Dependant Combustion Flue Air Opening...

  • Page 44: Single Pipe System-Vertical/Horizontal Installations

    10 (250) 12 (305) Max. equivalent length Contact Viessmann for vent length calculation a+b [ft. (m)] 200 (60) Note: If flexible vent or air-intake pipe are used, the total max. equivalent length will be reduced by 25% [150 ft. (45 m)].

  • Page 45: Two Pipe System-Vertical Exhaust/Vertical Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Vertical Exhaust / Vertical Air Intake The vent diameter of CM2 boilers can be reduced to 6” (150 mm) nominal vent size. See the following table for max. vent length applicable to vent reduction diameter.

  • Page 46: Two Pipe System-Horizontal Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Horizontal Exhaust / Horizontal Air Intake The vent diameter of CM2 boilers can be reduced to 6” (150 mm) nominal vent size. See the following table for max. vent length applicable to vent reduction diameter.

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

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Two Pipe System - Vertical Exhaust / Horizontal Air Intake The vent diameter of CM2 boilers can be reduced to 6” (150 mm) nominal vent size. See the following table for max. vent length applicable to vent reduction diameter.

  • Page 48: Single Pipe-Vertical Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Single Pipe System - Vertical Exhaust / Room Air Dependant The vent diameter of CM2 boilers can be reduced to 6” (150 mm) nominal vent size. See the following table for max. vent length applicable to vent reduction diameter.

  • Page 49: Single Pipe-Horizontal Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 Installation Instructions Single Pipe System - Horizontal Exhaust / Room Air Dependant The vent diameter of CM2 boilers can be reduced to 6” (150 mm) nominal vent size. See the following table for max. vent length applicable to vent reduction diameter.
  • Page 50 Vitocrossal 200 CM2 Installation Instructions...
  • Page 51 Vitocrossal 200 CM2 Installation Instructions...

This manual is also suitable for:

Vitocrossal 200 cm2 186Vitocrossal 200 cm2 246Vitocrossal 200 cm2 311

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