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Viessmann Vitocrossal 200 Installation Instructions Manual

Gas condensing boiler with cylinder burner
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Download this manual See also: Instruction Manual, Instruction and Installation Manual
Installation Instructions
for use by heating contractor
Vitocrossal 200
CM2 Series 186, 246 and 311
Gas condensing boiler with cylinder burner
Heating input:
663 to 1112 MBH
194 to 326 kW
VITOCROSSAL 200
H
5584 107 - 04 04/2015
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 186, 246 and 311 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...

  • Page 2: Safety, Installation And Warranty Requirements

    General Information Vitocrossal 200 CM2 186 to 311 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: Table Of Contents

    Table of Contents Vitocrossal 200 CM2 186 to 311 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 Safety Important Regulatory and Installation Requirements..5 Fiberglass wool and ceramic fiber material....5...
  • Page 4 Table of Contents Vitocrossal 200 CM2 186 to 311 Installation Page Venting General Venting Information........30 Installation steps (outline)........30 Recommended Venting Practice.......31 Approved venting materials........31 Vent termination location requirements (for installations in Canada)........32 Vent termination location requirements (for installations in the U.S.A.)........32 Flashing and storm collar installation......33...

  • Page 5: Safety

    Safety Vitocrossal 200 CM2 186 to 311 Installation Important Regulatory and Installation Requirements (continued) 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 6: For Installations On The Commonwealth Of Massachusetts

    Safety Vitocrossal 200 CM2 186 to 311 Installation 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...

  • Page 7: 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. (762 mm) venting applications. Do not attempt to common-vent the boiler with any Vent-air intake system must be properly installed and sealed.

  • Page 8: Working On The Equipment

    Safety/ General Information Vitocrossal 200 CM2 186 to 311 Installation Important Regulatory and Installation Requirements (continued) Working on the equipment The installation, adjustment, service, and maintenance of The completeness and functionality of field supplied this boiler must be performed by a licensed professional...

  • Page 9: Product Information

    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 186 to 311 Installation 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 186 to 311 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

    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 13: Safety Header

    Boiler Vitocrossal 200 CM2 186 to 311 Installation Boiler Connections (continued) Legend 1 Boiler return: (ANSI Weld neck flanges 2b in.) Safety Header 2 Boiler supply: (ANSI Weld neck flanges 2b in.) 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 186 to 311 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 15: Burner Installation

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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.

  • Page 16: Rails And Front Panels

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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.

  • Page 17: Combustion Air Adapter Burner Connection

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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 186 to 311 Installation 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 Sensor

    Boiler Vitocrossal 200 CM2 186 to 311 Installation Flue Gas Temperature Sensor Flue temperature sensor During boiler operation the flue gas temperature sensor The flue gas temperature sensors are connected directly sends a signal to the burner control and will disable the to the burner control.

  • Page 20: Rear Panels

    Boiler Vitocrossal 200 CM2 186 to 311 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 21: Sensors And Buffer Panel

    Boiler Vitocrossal 200 CM2 186 to 311 Installation Sensors and Buffer Panel The boiler water temperature sensor A is included in junction box shipping package. Power plug 40 is plugged into control. Burner cables 41 and 90 are included in the insulation shipping package.

  • Page 22: Top Panels

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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.

  • Page 23: Condensate Connection

    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 installed. Select a pump which is approved for condensing boiler applications.

  • Page 24: Gas Connections

    Boiler Vitocrossal 200 CM2 186 to 311 Installation Gas Connections Legend A Gas shut-off valve B Aux. low gas pressure switch C Low gas pressure switch D High gas pressure switch E Fan pressure switch F Test fire valve G Venturi...

  • Page 25: Valve Leak Test

    Boiler Vitocrossal 200 CM2 186 to 311 Installation Gas Connections (continued) 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 26 Boiler Vitocrossal 200 CM2 186 to 311 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 27: Burner Electrical Connections

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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).

  • Page 28: Front Panel (Door)

    Boiler Vitocrossal 200 CM2 186 to 311 Installation 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.

  • Page 29: Initial System Fill

    Unsuitable water quality may damage boiler. will be null and void. 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 30: Venting

    Venting Vitocrossal 200 CM2 186 to 311 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 31: Approved Venting Materials

    Venting Vitocrossal 200 CM2 186 to 311 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 32: Vent Termination Location Requirements (For Installations In Canada)

    Venting Vitocrossal 200 CM2 186 to 311 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 33: Flashing And Storm Collar Installation

    Venting Vitocrossal 200 CM2 186 to 311 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. To obtain flashings and storm collars, please contact your local vent material supplier.

  • Page 34: Vent Pipe Material

    Venting Vitocrossal 200 CM2 186 to 311 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 35: Vent Requirements

    Venting Vitocrossal 200 CM2 186 to 311 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 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 36: Direct Venting (Two Pipe System)

    Venting Vitocrossal 200 CM2 186 to 311 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 37: Side Wall Venting

    Venting Vitocrossal 200 CM2 186 to 311 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 38: Component Installation Guide

    Venting Vitocrossal 200 CM2 186 to 311 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 39: Installation Of Support System - Pp

    Venting Vitocrossal 200 CM2 186 to 311 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 40: Venting Options - Stainless Steel/Pp

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation Two Pipe System - Vertical Exhaust / Vertical Air Intake Flue a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table on page 41.

  • Page 41: Two Pipe System-Vertical Exhaust/Horizontal Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation Two Pipe System - Vertical Exhaust / Horizontal Air Intake Flue a - Equivalent length (exhaust) b - Equivalent length (air intake) Note: See table below.

  • Page 42: Single Pipe-Vertical Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation Single Pipe System - Vertical Exhaust / Room Air Dependant Flue Combustion Air Opening a - Equivalent length (exhaust) Note: See table on page 43. Single Pipe System - Horizontal Exhaust / Room Air Dependant...

  • Page 43: Single Pipe System-Vertical/Horizontal Installations

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation Single Pipe System - Vertical / Horizontal Installations Maximum allowable equivalent length - Stainless steel / PP Boiler Models CM2-186, -246, -311 Flue gas in. (mm)

  • Page 44: Two Pipe System-Vertical Exhaust/Vertical Air Intake

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation 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.

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

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation 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.

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

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation 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.

  • Page 47: Single Pipe-Vertical Exhaust / Room Air Dependent

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation 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.

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

    Venting Options - Stainless Steel / PP Vitocrossal 200 CM2 186 to 311 Installation 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.

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