Viessmann Vitocrossal 200 CM2 Series Quick start guide

VIESMANN Gas condensing boilers
87 to 1400 kW
VITOCROSSAL 200 Type CM2
VITOCROSSAL 300 Type CM3
VITOCROSSAL 300 Type CT3U
VITOCROSSAL 300 Type CT3B
VITOCROSSAL 300 Type CR3B
5822 449 GB 5/2013
Technical guide

Index
1. Vitocrossal 200, type CM2, 87 to
311 kW
1. 1 Product description ................................................................................................... 5
1. 2 Operating conditions ................................................................................................. 5
2. Vitocrossal 200, type CM2, 400 to
620 kW
2. 1 Product description ................................................................................................... 6
2. 2 Operating conditions ................................................................................................. 6
3. Vitocrossal 300, type CM3, 87 to
142 kW
3. 1 Product description ................................................................................................... 7
3. 2 Operating conditions ................................................................................................. 7
4. Vitocrossal 300, type CT3U, 400 to
630 kW
4. 1 Product description ................................................................................................... 8
4. 2 Operating conditions ................................................................................................. 8
5. Vitocrossal 300, type CT3B, 187 to
635 kW
5. 1 Product description ................................................................................................... 9
5. 2 Operating conditions ................................................................................................. 9
6. Vitocrossal 300, type CR3B, 787 to
1400 kW
6. 1 Product description ................................................................................................... 10
6. 2 Operating conditions ................................................................................................. 10
7. Installation accessories 7. 1 Specification ............................................................................................................. 11
■ Accessories for heating circuits ............................................................................ 11
■ Hydraulic system pipework for two-boiler system ................................................. 17
■ CO limiter for Vitocrossal 300, type CM3 .............................................................. 18
8. Design information 8. 1 Delivery, handling and siting ..................................................................................... 19
■ Delivery ................................................................................................................. 19
■ Handling and siting ............................................................................................... 19
■ Installation location ............................................................................................... 19
■ Safety equipment for the installation room for Vitocrossal 300, type CM3 ........... 20
8. 2 System design .......................................................................................................... 20
■ Performance limits in regulations .......................................................................... 20
■ Flow temperatures ................................................................................................ 20
■ Pump controlled pressure maintaining systems ................................................... 20
■ Safety temperatures .............................................................................................. 20
■ Requirements through heat load ........................................................................... 21
■ Selection of rated heating output .......................................................................... 21
8. 3 Water connection ...................................................................................................... 21
■ Heating connections ............................................................................................. 21
■ Connection for the utilisation of condensing technology ....................................... 21
■ Heating circuit pumps ........................................................................................... 22
■ System accessories .............................................................................................. 22
■ Sample applications .............................................................................................. 22
8. 4 Safety equipment ...................................................................................................... 22
■ General information .............................................................................................. 22
■ Safety accessories selection table for the Vitocrossal .......................................... 23
8. 5 Fuels ......................................................................................................................... 23
8. 6 Burner ....................................................................................................................... 24
■ Suitable burners .................................................................................................... 24
■ Burner installation ................................................................................................. 24
8. 7 Flue gas routing ........................................................................................................ 24
■ Flue systems ......................................................................................................... 24
■ Flue systems for condensing boilers ..................................................................... 25
■ Installation options for the Vitocrossal flue system ............................................... 26
8. 8 Flue system for the Vitocrossal, 87 to 635 kW ......................................................... 28
■ CE designation for the PPs flue systems for the Vitocrossal ................................ 29
■ Open flue operation with the Vitocrossal 200 and Vitocrossal 300 ....................... 31
■ Calculating the max. pipe lengths and pipe diameters of the PPs flue system when
using MatriX radiant burners ................................................................................. 32
■ Calculating the max. pipe lengths, pipe diameters and total burner draught in the
flue system when using third party burners .......................................................... 32
■ Balanced flue operation with the Vitocrossal 200 ................................................. 35
■ Individual components of the plastic flue system .................................................. 38
■ Connection with plastic flue pipe (PPs) to a moisture-resistant chimney (MR chim-
ney, negative pressure) ........................................................................................ 44
■ Stainless steel flue gas header for two-boiler system .......................................... 45
8. 9 Sound insulation ....................................................................................................... 47
■ Attenuating airborne noise .................................................................................... 48
■ Structure-borne noise attenuation ......................................................................... 48
Index
2VIESMANN Gas condensing boilers
5822 449 GB

8.10 Standard values for water quality ............................................................................. 48
■ Heating systems with rated operating temperatures in excess of 100 °C
(VDI 2035) ............................................................................................................. 48
■ Prevention of damage through corrosion on the water side ................................. 49
8.11 Frost protection ......................................................................................................... 49
8.12 Condensate and neutralisation ................................................................................. 50
■ Design notes regarding condensate drain pipe .................................................... 50
■ Neutralising systems ............................................................................................. 50
8.13 Intended use ............................................................................................................. 50
9. Control units 9. 1 Overview of boiler control units and control panels .................................................. 50
■ Single boiler systems ............................................................................................ 51
■ Multi boiler systems .............................................................................................. 52
■ Control panel installation ....................................................................................... 53
■ Switching points .................................................................................................... 54
9. 2 Components in the delivered condition ..................................................................... 54
■ Allocation to control unit types .............................................................................. 54
■ Boiler water temperature sensor ........................................................................... 54
■ Boiler water temperature sensor in conjunction with the Vitotronic 100,
type GC4B and Vitotronic 300, type GW4B .......................................................... 55
■ Cylinder temperature sensor ................................................................................. 55
■ Outside temperature sensor ................................................................................. 55
9. 3 Vitotronic 100, type GC1B, part no. 7498 901 .......................................................... 55
■ Specification .......................................................................................................... 55
■ Delivered condition ............................................................................................... 57
9. 4 Vitotronic 100, type GC4B, part no. 7441 811 .......................................................... 57
■ Specification .......................................................................................................... 57
■ Delivered condition ............................................................................................... 59
9. 5 Vitotronic 200, type GW1B, part no. 7498 902 ......................................................... 59
■ Specification .......................................................................................................... 59
■ Delivered condition ............................................................................................... 61
9. 6 Vitotronic 300, type GW2B, part no. 7498 903 ......................................................... 61
■ Specification .......................................................................................................... 61
■ Delivered condition ............................................................................................... 64
9. 7 Vitotronic 300, type GW4B, part no. 7441 813 ......................................................... 64
■ Specification .......................................................................................................... 64
■ Delivered condition ............................................................................................... 66
9. 8 Vitotronic 300-K, type MW1B, part no. 7498 906 ..................................................... 66
■ Specification .......................................................................................................... 66
■ Delivered condition ............................................................................................... 68
Index (cont.)
Gas condensing boilers VIESMANN 3
5822 449 GB

9. 9 Control unit accessories ........................................................................................... 69
■ Allocation of accessories according to control unit type ....................................... 69
■ Information regarding Vitotrol 200A and 300A ...................................................... 69
■ Vitotrol 200A ......................................................................................................... 69
■ Vitotrol 300A ......................................................................................................... 70
■ Information regarding the Vitotrol 200 RF and Vitotrol 300 RF ............................. 71
■ Vitotrol 200 RF ...................................................................................................... 71
■ Vitotrol 300 RF with table-top dock ....................................................................... 71
■ Vitotrol 300 RF with wall mounting bracket ........................................................... 72
■ Wireless base station ............................................................................................ 73
■ Wireless outside temperature sensor ................................................................... 74
■ Wireless repeater .................................................................................................. 74
■ Room temperature sensor .................................................................................... 74
■ Contact temperature sensor ................................................................................. 75
■ Immersion temperature sensor ............................................................................. 75
■ Sensor well ........................................................................................................... 75
■ Sensor well ........................................................................................................... 75
■ Sensor well ........................................................................................................... 75
■ Flue gas temperature sensor ................................................................................ 75
■ Mixer extension kit ................................................................................................ 76
■ Mixer motor for flanged mixers ............................................................................. 76
■ Immersion temperature controller ......................................................................... 76
■ Contact temperature controller ............................................................................. 77
■ Radio clock receiver .............................................................................................. 77
■ Plug-in adaptor for external safety equipment ...................................................... 77
■ Contactor relay ...................................................................................................... 78
■Mating plugs fA and lÖ ....................................................................................... 78
■ Mounting kit for control panel fitting ...................................................................... 78
■ Solar control module, type SM1 ............................................................................ 79
■ EA1 extension ...................................................................................................... 80
■ Vitocom 100, type LAN1 ....................................................................................... 80
■ Vitocom 100, type GSM2 ...................................................................................... 81
■ Vitocom 200, type LAN2 ....................................................................................... 82
■ Vitocom, type LAN3 .............................................................................................. 83
■ LON connecting cable for data exchange between control units .......................... 85
■ Extension of the connecting cable ........................................................................ 86
■ Terminator (2 pce) ................................................................................................ 86
■ LON communication module ................................................................................. 86
■ Vitogate 200, type EIB .......................................................................................... 86
9.10 On-site connections .................................................................................................. 86
■ Connection of on-site control units to the Vitotronic 100, type GC1B, in single boiler
systems ................................................................................................................. 86
■ Connection of on-site control units to the Vitotronic 100, type GC4B, in single boiler
systems ................................................................................................................. 87
■ Connection of on-site control units to EA1 extension in single boiler systems ..... 88
■ Additional functions for single boiler systems with Vitotronic 200, type GW1B or
Vitotronic 300, type GW2B or GW4B .................................................................... 89
■ Additional functions for single boiler systems with Vitotronic 200, type GW1B or
Vitotronic 300, type GW2B or GW4B via EA1 extension ...................................... 89
■ Additional functions for multi boiler systems with Vitotronic 300-K, type MW1B or
Vitotronic 100, type GC1B or GC4B via LON ....................................................... 90
■ Connection of on-site control units to EA1 extension in multi boiler systems with
on-site cascade control unit .................................................................................. 91
■ Boiler sequence control with on-site cascade control unit — connections to the
Vitotronic 100, type GC1B .................................................................................... 92
■ Boiler sequence control with on-site cascade control unit — connections to the
Vitotronic 100, type GC4B .................................................................................... 93
■ Hook-up of on-site control units via LON .............................................................. 94
10. Appendix 10. 1 Important safety regulations and requirements ........................................................ 95
■ General information .............................................................................................. 95
■ Gas installation ..................................................................................................... 95
■ Pipe connections ................................................................................................... 95
■ Electrical installation ............................................................................................. 95
■ Operating instructions ........................................................................................... 95
■ Flue system ........................................................................................................... 95
■ Fill and top-up water ............................................................................................. 95
■ Checks as part of the Building Regulations approval procedure .......................... 95
11. Keyword index .............................................................................................................................................. 96
Index (cont.)
4VIESMANN Gas condensing boilers
5822 449 GB

1.1 Product description
Gas condensing boiler with MatriX radiant burner for natural gas E and
LL, for open or balanced flue operation
For operation with a modulating boiler water temperature
Permissible operating temperature up to 95 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure 4 bar (0.4 MPa)
■ CE designation: CE-0085BQ0021 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23, B23P, C13, C33, C43, C53, C63, C83
■ Standard seasonal efficiency [to DIN]: up to
97 % (Hs) [gross cv] / 108 % (Hi) [net cv].
■ The stainless steel, corrosion-resistant Inox-Crossal heat exchanger
ensures high operational reliability and a long service life.
■ Inox-Crossal heat exchanger for highly effective heat transfer and
high condensation rate.
■ Self-cleaning effect through smooth stainless steel surface.
■ Clean combustion through low combustion chamber loading and
straight-through design.
■ MatriX radiant burner for particularly quiet and environmentally
responsible operation with a modulating range of 33 to 100 %.
■ Either open flue or balanced flue operation.
■ All hydraulic connections can be fitted from above.
■ Easy to use Vitotronic control unit with plain text and graphic display.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ Multi boiler system with pre-assembled accessories on the hydraulic
and flue gas side.
1.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Low-end boiler water temperature None
4. Lower boiler water temperature with frost protection 10 °C – ensured through the Viessmann control unit
5. Two-stage burner operation None
6. Modulating burner operation None
7. Reduced mode None – total reduction is possible
8. Weekend setback None – total reduction is possible
Vitocrossal 200, type CM2, 87 to 311 kW
Gas condensing boilers VIESMANN 5
5822 449 GB
1

2.1 Product description
Gas condensing boiler with MatriX cylinder burner for natural gas E,
LL and LPG, for open or balanced flue operation
For operation with a modulating boiler water temperature
Permissible operating temperature up to 95 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure 6 bar (0.6 MPa)
■ CE designation: CE-0085BQ0021 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23, B23P, C13, C33, C43, C53, C63, C83
■ Condensing Unit with gas burner, 400 to 620 kW, as dual cascade
up to 1240 kW.
■ Standard seasonal efficiency [to DIN]: up to
97 % (Hs) [gross cv] / 108 % (Hi) [net cv].
■ The stainless steel, corrosion-resistant Inox-Crossal heat exchanger
ensures high operational reliability and a long service life.
■ Inox-Crossal heat exchanger for highly effective heat transfer and
high condensation rate.
■ Self-cleaning effect through smooth stainless steel surface.
■ Clean combustion through low combustion chamber loading and
straight-through design.
■ MatriX cylinder burner for environmentally responsible operation
with a modulation range from 20 to 100 %.
■ Either balanced flue or open flue operation.
■ All hydraulic connections on the system side can be made from
above.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ Easy to use Vitotronic control unit with plain text and graphic display.
2.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Lower boiler water temperature None
4. Reduced mode None – total reduction is possible
5. Weekend setback None – total reduction is possible
Vitocrossal 200, type CM2, 400 to 620 kW
6VIESMANN Gas condensing boilers
2
5822 449 GB

3.1 Product description
Gas condensing boiler with MatriX radiant burner for natural gas E and
LL
With two return connectors
For operation with a modulating boiler water temperature
Permissible operating temperature up to 95 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure 4 bar (0.4 MPa)
■ CE designation: CE-0085BN0569 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23
■ Standard seasonal efficiency [to DIN]: up to
98 % (Hs) [gross cv] / 109 % (Hi) [net cv].
■ Stainless steel Inox-Crossal heat exchanger for efficient utilisation
of condensing technology – self-cleaning effect through smooth
stainless steel surfaces.
■ Modulating MatriX gas burner with a wide modulation range (30 to
100 %) for particularly quiet, economical and environmentally
responsible operation.
■ Excellent controllability and reliable heat transfer due to wide water
galleries and high water content.
■ Second return connector for low return temperatures resulting in an
especially intensive utilisation of condensing technology.
■ Easy to use Vitotronic control unit with plain text and graphic display.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ A strong draught in the flue outlet enables long flue and ventilation
air pipe runs.
3.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Low-end boiler water temperature None
4. Lower boiler water temperature with frost protection 10 °C – ensured through the Viessmann control unit
5. Two-stage burner operation None
6. Modulating burner operation None
7. Reduced mode None – total reduction is possible
8. Weekend setback None – total reduction is possible
Vitocrossal 300, type CM3, 87 to 142 kW
Gas condensing boilers VIESMANN 7
5822 449 GB
3

4.1 Product description
Gas condensing boiler with MatriX cylinder burner for natural gas E
and LL, for open or balanced flue operation
With two return connectors
For operation with a modulating boiler water temperature
Permissible operating temperature up to 95 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure 5.5 bar (0.55 MPa)
■ CE designation: CE-0085AQ0257 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23, B23P, C33, C43, C53, C63, C83, C93
■ Condensing Unit with MatriX cylinder burner as two-boiler system
up to 1260 kW.
■ Standard seasonal efficiency [to DIN]: up to
98 % (Hs) [gross cv] / 109 % (Hi) [net cv].
■ The stainless steel, corrosion-resistant Inox-Crossal heat exchanger
ensures high operational reliability and a long service life.
■ Inox-Crossal heat exchanger for highly effective heat transfer and
high condensation rate.
■ Self-cleaning effect through smooth stainless steel surface.
■ MatriX cylinder burner for particularly quiet and environmentally
responsible operation with a modulating range of 33 to 100 %.
■ Either open flue or balanced flue operation.
■ Cascade with pre-assembled accessories on the hydraulic and flue
gas side.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ Easy to use Vitotronic control unit with plain text and graphic display.
4.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Low-end boiler water temperature None
4. Lower boiler water temperature with frost protection 10 °C – ensured through the Viessmann control unit
5. Two-stage burner operation None
6. Modulating burner operation None
7. Reduced mode None – total reduction is possible
8. Weekend setback None – total reduction is possible
Vitocrossal 300, type CT3U, 400 to 630 kW
8VIESMANN Gas condensing boilers
4
5822 449 GB

5.1 Product description
Gas condensing boiler for natural gas E, LL and LPG
With two return connectors
Boiler also available in sections
For operation with a modulating boiler water temperature
Permissible operating temperature up to 100 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure
■ Vitocrossal 300 with 187 to 314 kW - 4 bar (0.4 MPa)
■ Vitocrossal 300 with 408 to 635 kW - 5.5 bar (0.55 MPa)
■ Up to 314 kW with MatriX radiant burner for natural gas E and LL
■ CE designation: CE-0085AQ0257 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23
■ Standard seasonal efficiency [to DIN]: up to
98 % (Hs) [gross cv] / 109 % (Hi) [net cv].
■ The stainless steel, corrosion-resistant Inox-Crossal heat exchanger
ensures high operational reliability and a long service life.
■ Inox-Crossal heat exchanger for highly effective heat transfer and
high condensation rate.
■ Self-cleaning effect through smooth stainless steel surface.
■ Clean combustion through low combustion chamber loading and
straight-through design.
■ MatriX radiant burner up to 314 kW for particularly quiet and envi-
ronmentally responsible operation, with a modulation range from 33
to 100 %.
■ With either ELCO or Weishaupt pressure-jet gas burner.
■ Two return connectors for hydraulic connection optimised for con-
densing technology.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ Easy to use Vitotronic control unit with plain text and graphic display.
5.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Low-end boiler water temperature None
4. Lower boiler water temperature with frost protection 10 °C – ensured through the Viessmann control unit
5. Two-stage burner operation None
6. Modulating burner operation None
7. Reduced mode None – total reduction is possible
8. Weekend setback None – total reduction is possible
Vitocrossal 300, type CT3B, 187 to 635 kW
Gas condensing boilers VIESMANN 9
5822 449 GB
5

6.1 Product description
Gas condensing boiler for natural gas E, LL and LPG
With two return connectors
Also available in sections
For operation with a modulating boiler water temperature
Permissible operating temperature up to 100 °C
Permissible safety temperature up to 110 °C
Permissible operating pressure 6 bar (0.6 MPa)
■ CE designation: CE-0085AU0315 in accordance with the Gas Appli-
ances Directive.
■ Boiler categories: B23
■ Standard seasonal efficiency [to DIN]: up to
98 % (Hs) [gross cv] / 109 % (Hi) [net cv].
■ The stainless steel, corrosion-resistant Inox-Crossal heat exchanger
ensures high operational reliability and a long service life.
■ Inox-Crossal heat exchanger for highly effective heat transfer and
high condensation rate.
■ Self-cleaning effect through smooth stainless steel surface.
■ Clean combustion through low combustion chamber loading and
straight-through design.
■ With either ELCO or Weishaupt pressure-jet gas burner.
■ Two return connectors for hydraulic connection optimised for con-
densing technology.
■ Hydraulically straightforward connection, no minimum flow rate, no
low loss header necessary, particularly low pressure drop on the
water side.
■ Easy to use Vitotronic control unit with plain text and graphic display.
6.2 Operating conditions
Note
For water quality requirements, see page 48.
Requirements
1. Heating water flow rate None
2. Boiler return temperature (minimum value) None
3. Low-end boiler water temperature None
4. Lower boiler water temperature with frost protection 10 °C – ensured through the Viessmann control unit
5. Two-stage burner operation None
6. Modulating burner operation None
7. Reduced mode None – total reduction is possible
8. Weekend setback None – total reduction is possible
Vitocrossal 300, type CR3B, 787 to 1400 kW
10 VIESMANN Gas condensing boilers
6
5822 449 GB

7.1 Specification
Accessories for heating circuits
Divicon heating circuit distribution
For boilers up to 314 kW
Specification
Design and function
■ 1 to 4 heating circuits can be connected to the flow distributor and
return collector.
■ Free connections are closed via dummy flanges (part of the standard
delivery).
■ The flow distributor and return collector can optionally be arranged
on the r.h. or the l.h. side of the boiler.
■ Thermal insulation for the Divicon heating circuit distributor is part of
the standard delivery.
Divicon heating circuit distributor, installed adjacent to the boiler
for Vitocrossal 200 and 300
Do not use the prefabricated pipe connections for these boilers. The
Divicon heating circuit distributor can also be placed near the boiler
(as an alternative to wall mounting) by using the separate adjustable
feet and on-site pipe connections.
280 - 400
Divicon heating circuit distributor, wall mounted
for Vitocrossal 200 and 300
500
c
= 307
b
a
1630
360
910
210
70
420420420
E
E
EL
EL
E Drain
EL Air vent valve
Dimensions
Rated boiler heating output kW 87 to
187
246 to
314
a (DN 25 + DN 32) mm 1186 1196
b (DN 40 + DN 50) mm 1586 1606
c mm 170 173
Connections for an additional consumer (e.g. DHW cylinder)
2 pipe connectors G 1½ (male thread) on the back of the flow distrib-
utor and return manifold.
Installation accessories
Gas condensing boilers VIESMANN 11
5822 449 GB
7

21080
67
19072,5
Heating circuit connections
Heating circuit connection DN 25 and DN 32 (shown with mixer)
210
852
AHeating flow
BHeating return
CBall valve
DCheck valve
ECirculation pump
F3-way mixer
Heating circuit connection DN 40 and DN 50 (shown with mixer)
210
1252
AHeating flow
BHeating return
CBall valve
DCheck valve
ECirculation pump
F3-way mixer
Heating output which can be connected to the heating circuit
connections at (ΔT = 20 K)
Heating circuit connection kW
DN 25 40
DN 32 70
DN 40 140
DN 50 170
Wilo heating circuit pumps, differential pressure-dependent
(Adjustable from proportional pressure to constant pressure)
Motor protection
Integral motor protection in terminal boxes for all differential pressure
settings. Contact breaking capacity for central fault message 1 A,
250 V~.
Installation accessories (cont.)
12 VIESMANN Gas condensing boilers
7
5822 449 GB

230 V~, 50 Hz
Heating circuit connection DN 25 32 40 50
Pump type Stratos PICO 25/1-6 Stratos PICO 30/1-6 Stratos 40/1-8 Stratos 50/1-8
Speed range n min-1 1200-4230 1200-4230 1400-4800 1400-4800
Power consumption P1W 3-40 3-40 12-310 12-310
Current I A max. 0.35 max. 0.35 0.22-1.37 0.22-1.37
Head
Heating circuit pump DN 25 and DN 32
0
100
200
300
400
012
Flow rate in m³/h
Draught
500
600
3 4
Max.
Min.
p-v
0
10
20
30
40
50
60
kPa mbar
Proportional pressure
0
100
200
300
400
0 1 2
Flow rate in m³/h
Draught
500
600
3 4
Max.
Min.
p-c
5
kPa
mbar
0
10
20
30
40
50
60
700 70
Constant pressure
Head
Heating circuit pump DN 40 and DN 50
Flow rate in m³/h
0 2 4 6 8 10 12 14
100
200
0
300
400
500
600
700
800
900
Head
Max.
Min.
10
20
0
30
40
50
60
70
80
90
kPa mbar
16
1000 100
Proportional pressure
Flow rate in m³/h
0 2 4 6 8 10 12 14
100
200
0
300
400
500
600
700
800
900
Head
Max.
Min.
kPa mbar
10
20
0
30
40
50
60
70
80
90
16
1000 100
Constant pressure
Electrical connection
Heating circuit pump DN 25 and DN 32
A
L N
L N 20
AConnecting cable with plug-in connection
Electrical connection
Heating circuit pump DN 40 and DN 50
L N PE SSM
1-230 V
BU
BK
BK
BN
L N 20
T
0 ... 10 V
DP
*
Ext.
off
BN
GNYE
BU
ATerminals in the pump
B4-core cable for starting/stopping a pump and for pump fault mes-
sage
CCentral fault message facility
DExternal starting/stopping of the pump
Installation accessories (cont.)
Gas condensing boilers VIESMANN 13
5822 449 GB
7

EConnection via the contactor in the control panel or contactor
relay, part no. 7814 681
FPlug sÖ for connection to the Vitotronic
G3-core cable for power supply to the pump
Colour coding to DIN IEC 60757
BK Black
BK* Black wire with imprint
BN Brown
BU Blue
GNYE Green/yellow
Grundfos heating circuit pumps, differential pressure-dependent
(Adjustable from proportional pressure to constant pressure)
Motor protection
The motor and the electrical equipment are protected against thermal
overload. No external motor protection is required.
230 V~, 50 Hz
Heating circuit connec-
tion
DN 25 32 40 50
Pump type Alpha 2 25-60 Alpha 2 32-60 MAGNA
UPE 40-120
MAGNA
UPE 50-60
Speed range n min-1 – – 900-3580 680-1970
Power consumption P1W 5-45 5-45 25-445 32-335
Current I A 0.05-0.38 0.05-0.38 0.16-2.0 0.2-1.51
Head
Heating circuit pump DN 25 and DN 32
50
60
500
600
1 1.5 2 2.5 3 3.5
Head mbar
300
40
20
0
10
30
400
200
0
100
kPa
0 0.5
Flow rate in m³/h
A
B
C
D
AOperating range in differential pressure-dependent mode
Operation in stages
BStage 1
CStage 2
DStage 3
Head
Heating circuit pump DN 40
200
0
400
600
800
1000
0 2 4 6 8 10 12 14
Head
1200
1400
16 18 20
Flow rate in m³/h
mbar kPa
20
0
40
60
80
100
120
140
Min.
Max.
Proportional pressure
0 2 4 6 8 10 12 14 16 18 20
Flow rate in m³/h
Min.
Max.
200
0
400
600
800
1000
Head
1200
1400
mbar kPa
20
0
40
60
80
100
120
140
Constant pressure
Head
Heating circuit pump DN 50
600
700
100
0
200
300
400
500
0
Head
4 8 12 16 20 24 28 32
Flow rate in m³/h
Min.
Max.
mbar
60
70
10
0
20
30
40
50
kPa
Proportional pressure
Installation accessories (cont.)
14 VIESMANN Gas condensing boilers
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600
700
100
0
200
300
400
500
0
Head
4 8 12 16 20 24 28 32
Flow rate in m³/h
Min.
Max.
kPa
mbar
60
70
10
0
20
30
40
50
Constant pressure
Electrical connection
Heating circuit pump DN 25 and DN 32
A
L N
L N 20
AConnecting cable with plug-in connection
Electrical connection
Heating circuit pump DN 40 and DN 50
CNO
BN BU GNYE
S
T
O
P
H
G
E F
D
K
L
L N
A
NC
B
1 2 3 8 7
C
BN
N 20
BU BK BK
APower supply
BSignal output
CON/OFF
DCable for starting/stopping a pump and pump fault message (4-
core)
ECentral fault message facility
FExternal starting/stopping of the pump
GConnection via the contactor in the control panel or contactor
relay, part no. 7814 681
HPlug sÖ for connection to the Vitotronic
K3-core cable for power supply to the pump
Colour coding to DIN IEC 60757
BK Black
BK* Black wire with imprint
BN Brown
BU Blue
GNYE Green/yellow
Installation accessories (cont.)
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Residual head
Residual head of the heating circuits
Deduct the pressure drop of the mixer and the boiler circuit (boiler,
pipework, flow distributor and return collector) from the pump head.
The total water volume of all heating circuits should be taken into con-
sideration in the boiler circuit.
Boiler circuit pressure drop
(Boiler + pipework + flow distributor and return collector + heating cir-
cuit connection without mixer)
1
2
3
4
5
10
15
20
30
40
50
100
1 2 34 5 10 15 20
Flow rate in m³/h
Pressure drop
CBA
0.1
0.2
0.3
0.4
0.5
1
1.5
2
3
4
5
10
kPa mbar
ADN 65: Vitocrossal 300, 87 to 142 kW,
BDN 65: Vitocrossal 300, 187 and 248 kW,
CDN 80: Vitocrossal 300, 314 kW,
Mixer pressure drop
1
2
5
10
20
50
100
200
500
0.2 0.5 12510 20
Throughput in m³/h
Pressure drop
D
C
BA
kPa mbar
0.1
0.2
0.5
1
2
5
10
20
50
0.1
ADN 25
BDN 32
CDN 40
DDN 50
Note
For the pressure drop of the pipe connections between the boiler and
distributor, 6 bends (90°) and 5 m pipe length are factored in. If con-
siderably different lengths and shapes are used on-site, calculate and
factor in the additional pressure drop levels.
Example for calculating the residual head
Heating system with:
– Divicon heating circuit distributor DN 80
– Heating cir-
cuit 1:
1 heating circuit connection DN 25 without mixer, heating output 35 kW, flow rate 1.5 m3/h
– Heating cir-
cuit 2:
1 heating circuit connection DN 32 with mixer, heating output 60 kW, flow rate 2.5 m3/h
– Heating cir-
cuit 3:
1 heating circuit connection DN 50 with mixer, heating output 150 kW, flow rate 6.5 m3/h
Total flow rate 10.5 m3/h
Boiler circuit pressure drop
Boiler + pipe connections + flow distributor and return collector + heat-
ing circuit connection (except mixer) (see diagram) = 30 mbar
(3 kPa)
Mixer pressure drop
(see diagram)
Mixer DN 32 50
Pressure drop mbar 18 22
kPa 1.8 2.2
Sum of the boiler circuit pressure drop and heating circuit connection pressure drop
Heating circuit 1: 30 mbar (3 kPa)
Heating circuit 2: 30 mbar + 18 mbar = 48 mbar (4.8 kPa)
Installation accessories (cont.)
16 VIESMANN Gas condensing boilers
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Heating circuit 3: 30 mbar + 22 mbar = 52 mbar (5.2 kPa)
Residual head of the individual heating circuits
With Wilo circulation pump
Heating circuit 1 2 3
Head of the circulation pump (adjustable) mbar 100 to 400 100 to 280 100 to 760
kPa 10 to 40 10 to 28 10 to 76
Pressure drop, boiler circuit + heating circuit connection mbar 30 48 52
kPa 3 4.8 5.2
Residual head (adjustable) mbar 70 to 370 52 to 232 48 to 708
kPa 7 to 37 5.2 to 23.2 4.8 to 70.8
With Grundfos circulation pump
Heating circuit 1 2 3
Head of the circulation pump (adjustable) mbar 100 to 400 100 to 260 150 to 520
kPa 10 to 40 10 to 26 15 to 52
Pressure drop, boiler circuit + heating circuit connection mbar 30 48 52
kPa 3 4.8 5.2
Residual head (adjustable) mbar 70 to 370 52 to 212 98 to 468
kPa 7 to 37 5.2 to 21.2 9.8 to 46.8
Vitocontrol control panel
(On request)
Control panel for regulating the heating system in conjunction with a
Divicon heating circuit distributor.
The control panel comprises all components required for the control
and monitoring of the heating system.
The system is designed so that other equipment can be installed next
to the control equipment of 1 to 4 boilers, such as: Vitotronic 300-K
(type MW1B), Vitotronic 200-H (type HK1B or HK3B), pump control
units, measuring devices, time switches etc.
Hydraulic system pipework for two-boiler system
For two-boiler systems up to 622 kW with Vitocrossal 200, type CM2
a
1Flow manifold and return collector
2Motorised butterfly valves
3Mating flanges with gaskets
Dim. a: 35 mm (boiler clearance with fitted thermal insulation)
Rated output in kW Int. dia.
Single boiler Dual-boiler system
87
115
142
174
230
284
DN 50/65
186
246
311
372
492
622
DN 65/80
Installation accessories (cont.)
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For two-boiler systems up to 1260 kW with Vitocrossal 300, type CT3U
B
A
C
D
D
B
a
150
E
E
AFlow manifold
BMating flanges with gaskets
CReturn collector
DMotorised butterfly valves
EBoiler return connector 2
Dim. a: 1550 mm
Rated heating output in kW Nominal diameter
Single boiler Two-boiler system
400
500
630
800
1000
1260
DN 100/125
Note
If using hydraulic system pipework part no. Z006 033, seal the second
return connectors E with blank flanges.
If the second return connectors E are used on site, install butterfly
valves D to the flow connectors.
CO limiter for Vitocrossal 300, type CM3
Part no. 7499 330
A monitoring device that safely shuts down the boiler in the event of
carbon monoxide being released.
Wall mounting in the ceiling area near the boiler.
Can be used for boilers built from 2004 onwards.
Components:
■ Casing with integrated CO sensor, relay and displays for operation
and alarm.
■ Fixing materials.
■ Power cable (2.0 m long).
■ Connecting cable – relay for burner shutdown (2.0 m long).
70
45
117
Specification
Rated voltage 230 V~
Rated frequency 50 Hz
Power consumption 3.5 W
Rated breaking capacity of the relay out-
put
8 A 230 V~
Alarm threshold 40 ppm CO
Safety category II
IP rating IP 20 to EN 60529; ensure
through design/installation
Permissible ambient temperature 70 °C
Installation accessories (cont.)
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8.1 Delivery, handling and siting
Delivery
We deliver the equipment to site on a vehicle with crane and will unload
the equipment, subject to there being no special hindrance.
Handling and siting
A sufficient number of lifting eyes is provided on each boiler, to which
lifting gear may be attached.
Vitocrossal 300, type CT3B, with 187 to 635 kW can be delivered in
sections upon request. The front part of the combustion chamber can
then be removed for easier handling (chargeable option; please state
when ordering).
The Vitocrossal 300, type CR3B boilers can be supplied with a split
combustion chamber and heat exchanger for individual handling. The
linear base rails simplify handling. Our experts can undertake the han-
dling and siting on prepared foundations upon request (chargeable
option).
The boilers may be placed onto concrete without special foundations.
However, to facilitate cleaning of the boiler room it is advisable to posi-
tion the boiler on a plinth.
For recommended minimum wall clearances for installation and main-
tenance work, see the datasheet of the respective boiler.
Anti-vibration boiler supports may be used if structure-borne noise
attenuation is required.
Installation location
General requirements
The installation room must meet the standards laid down by the Fire
Regulations of the respective country. In rooms where air contamina-
tion through halogenated hydrocarbons may occur, such as hairdress-
ing salons, printing shops, chemical cleaners, laboratories etc., the
boiler may only be installed if adequate measures can be taken to
provide a supply of uncontaminated combustion air. If in doubt, please
contact us.
Boilers should not be installed in areas subject to dusty or very humid
conditions. The installation room must be kept free from frost and must
be adequately ventilated. If these instructions are not observed, any
consequential boiler damage directly related to any of these causes is
excluded from our warranty. These boilers are particularly suitable for
installation in attics. They require no high chimneys as they are oper-
ated with a pressurised combustion chamber.
Requirements of the Muster-Feuerungsverordnung [Sample
Combustion Ordinance - Germany]
Requirements for installation rooms are listed in the "Sample Com-
bustion Ordinance". The Building Regulations of each country apply.
Combustion air supply
For open flue combustion equipment with a total rated heating output
in excess of 50 kW, the combustion air supply is deemed to have been
verified if the combustion equipment is located in rooms that provide
an aperture or duct leading outdoors. The cross-section of the aperture
must be at least 150 cm2 and must be 2 cm2 larger for each additional
kW above 50 kW rated heating output. Pipes must be sized to provide
equivalent flow rates. The required cross-section may be split over a
maximum of 2 apertures or pipes.
A
A = 150 cm² + 2 kW
cm² x (Σ²n – 35 kW)
Σ²n = sum of all rated heating outputs in kW
Combustion air apertures and pipes must not be closed or blocked if
installed safety equipment cannot adequately ensure that the com-
bustion equipment can only be operated when the aperture is open.
The required cross-section must not be blocked by any closure or
grille. An adequate combustion air supply can also be assured by other
means.
Installation locations for combustion equipment
Only install combustion equipment for gaseous or liquid fuels with a
total rated heating output in excess of 50 kW in areas meeting the
following conditions:
■ Not used for other purposes, except the installation of heat pumps,
CHP modules or permanently installed internal combustion engines
as well as the storage of fuels
■ No openings leading to other rooms, except doorways
■ Doors tight and self-closing
■ Ventilation facility
The burner and the fuel supply of the combustion equipment must be
able to be shut down at any time by an emergency stop switch installed
outside the installation room. Provide a sign adjacent to the emergency
stop switch that reads "EMERGENCY STOP SWITCH – COMBUS-
TION".
As an alternative to these requirements for installation rooms, com-
bustion equipment may also be installed in other rooms subject to one
of the following conditions:
■ The utilisation of these rooms makes this necessary and the com-
bustion equipment can be safely operated.
■ These rooms are located in a stand-alone building, which is only
used for the operation of the combustion equipment and as a fuel
store.
Further requirements regarding the installation of combustion
equipment
Fuel lines must be equipped with a device directly upstream of gas
combustion equipment installed in boiler rooms which meets the fol-
lowing conditions:
■ It automatically shuts off the fuel supply in case of an external ther-
mal load in excess of 100 °C.
■ It is designed so that up to a temperature of 650 °C and over a period
of at least 30 minutes, not more than 30 l/h (measured as air flow
rate) can flow through or out of the fuel line.
Design information
Gas condensing boilers VIESMANN 19
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Combustion equipment for LPG (propane, butane and their mixtures)
may only be installed in rooms whose floor is more than 1 m below
ground level at every point, subject to the following conditions:
■ The combustion equipment is equipped with a flame monitoring
device.
■ It is ensured that LPG cannot escape from the fuel lines inside the
installation room in dangerous quantities or will be extracted safely
via a mechanical ventilation system, even if the combustion equip-
ment has been switched off.
Combustion equipment must be installed at a sufficient distance from
combustible materials and fitted furniture, or be shielded from them, to
ensure the temperature on such materials/furniture does not exceed
85 °C when the combustion equipment is delivering the rated heating
output. Alternatively, maintain a distance of at least 40 cm.
Safety equipment for the installation room for Vitocrossal 300, type CM3
Viessmann boilers are tested and approved in accordance with all
safety regulations and are therefore fail-safe. Unpredictable, external
factors may, in the rarest of cases, lead to the potentially harmful
escape of carbon monoxide (CO). For this case, we recommend using
a CO limiter. This can be ordered as a separate accessory (part no.
7499 330).
8.2 System design
Performance limits in regulations
In many regulations, the conditions to be met are subject to the rated
boiler heating output. For this, the output at TF/TR 80/60 °C is deci-
sive.
However, the output levels given in this technical guide relate to the
specification at TF/TR 50/30 °C (type CM2, CM3, CT3U and CR3B)
and 40/30 °C (type CT3B), which is now commonly applied to con-
densing boilers.
The rated heating outputs at both TF/TR can be found in the table on
page 21.
Flow temperatures
To keep distribution losses to a minimum, we recommend that the:
■ Heat distribution system and the
■ DHW heating is designed for a max. of 70 °C (flow temperature).
On boilers supplied with a boiler control unit, the max. boiler water
temperature is limited to 75 °C. The flow temperature may be
increased by adjusting the temperature controller.
Pump controlled pressure maintaining systems
In heating systems with automatic pressure maintaining systems, and
in particular pump controlled systems with integral deaeration, we rec-
ommend the installation of a diaphragm expansion vessel for individual
boiler protection. This reduces the frequency and level of pressure
fluctuations. This contributes considerably to improved operational
reliability and longer service life of the system components. Failure to
observe these recommendations may result in damage to the boiler or
to other system components.
Boiler output (kW) Diaphragm expansion vessel
Capacity in litres
up to 300 50
up to 500 80
up to 1000 140
up to 2000 300
up to 5000 800
up to 10,000 1600
Furthermore ensure that only pump controlled pressure maintaining
systems that are sealed against corrosion and protected against oxy-
gen ingress into the heating water are used. Otherwise damage to the
system through oxygen corrosion can result. Pump controlled pres-
sure maintaining systems with atmospheric deaeration through cycli-
cal pressure release create a central post-ventilation of the heating
system. However, this does not represent oxygen removal in the sense
of corrosion protection as described in VDI 2035 Sheet 2.
Safety temperatures
Viessmann boilers correspond to EN 303 and DIN 4702 and all are
type-tested. They are suitable for installation in sealed heating sys-
tems to EN 12828. Permiss. flow temperatures (= safety tempera-
tures): up to 110 °C. Max. achievable flow temperature: approx. 15 K
below the safety temperature.
High limit safety cut-out of the boiler control unit
Delivered condition Adjustable to
110 °C 100 °C
For the Vitocrossal, the high limit safety cut-out must be changed over
to 100 °C.
Note
Once changed, the hydraulic-mechanical high limit safety cut-out can-
not be reset to the higher value.
Design information (cont.)
20 VIESMANN Gas condensing boilers
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