Viessmann Vitocrossal 200 CM2 Series User manual

Installation Instructions
VITOCROSSAL 200
5607 705 - 05 10/2014
for use by heating contractor
Vitocrossal 200
CM2 Series
Gas condensing boiler with cylinder burner
Read and save these instructions
for future reference.
Please file in Service Binder
Heating input: 663 to 1112 MBH
194 to 326 kW
Product may not be exactly as shown
H
IMPORTANT

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Vitocrossal 200 CM2 Installation Instructions
Safety, Installation and Warranty Requirements
General Information
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. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
WARNING
Installers must follow local regulations with respect
to installation of carbon monoxide detectors.
Follow the Viessmann maintenance schedule of the
boiler in the “Service Instructions” manual.
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to
Viessmann equipment.
For a listing of chemicals which
cannot be stored in or near the
boiler room, please see section
entitled “Mechanical Room”.
in this manual.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Carbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.
For information pertaining to the
proper installation, adjustment, service
and maintenance of this equipment to
avoid formation of carbon monoxide,
please see section entitled “Combustion
air supply” and “Venting information”
in this manual.
Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Mechanical Room” in this manual.
Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Information” in this manual. All
products of combustion must be
safely vented to the outdoors.

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Vitocrossal 200 CM2 Installation Instructions Table of Contents
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
Important Regulatory and Installation Requirements........5
Fiberglass wool and ceramic fiber material..................5
First aid measures....................................................5
Codes.....................................................................5
Mechanical room.....................................................5
For installations on the Commonwealth of
Massachusetts........................................................6
For polypropylene venting systems only....................7
Venting clearance to combustibles
(Stainless Steel / Polypropylene)................................7
Working on the equipment.......................................8
Technical literature..................................................8
About these Installation Instructions..............................8
Product Information....................................................9
Mechanical Room.......................................................9
For Retrofit Applications..............................................9
Recommended Minimum Service Clearances. ...............10
Preparing the Boiler...................................................11
Flex Hose Air Intake Adaptor......................................11
Boiler Insulation........................................................12
Boiler Connections....................................................12
Water side connection...........................................12
Safety Header.......................................................13
Hydrostatic Test Procedure........................................14
Burner Installation.....................................................15
Burner Hinge Reinstallation (if required).......................15
Rails and Front Panels................................................16
Combustion Air Flex Hose.........................................16
Combustion Air Adapter Burner Connection.................17
SidePanels.................................................................18
Side Panels (front)....................................................18
Flue Gas Temperature Switch.....................................19
Installing the Flue Gas Temperature Switch..................19
Wiring the Flue Gas Temperature Switch.....................19
Rear Panels.............................................................20
Boiler Control and Junction Box..................................20
Gas Flue Temperature Switch Connection....................21
Sensors and Buffer Panel...........................................21
Top Panels...............................................................22
Gas Flue Connections................................................22
Condensate Connection.............................................23
Gas Connections........................................................24
Gas valve flange installation...................................24
Valve leak test.....................................................25
Burner Electrical Connections....................................26
Front Panel (door)....................................................27
Boiler Piping in Heating / Cooling Application................27
Initial System Fill......................................................28
Introduction
Safety
General Information
Boiler
Page

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Vitocrossal 200 CM2 Installation Instructions
Table of Contents
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
Requirement for UL/ULC listed Rigid PP
Vent Pipe Material...................................................33
Requirements for PP and stainless steel....................33
Vent system suppliers............................................33
VentRequirements..................................................34
Combustion air supply, room air dependant
application only.....................................................34
Direct Venting (Two Pipe System)...............................35
Side wall vent termination [stainless steel, CPVC or PP]...35
Side Wall Venting....................................................36
Side wall vent termination [stainless steel or PP]........36
Component Installation Guide.....................................37
Flashing and storm collar installation........................37
Vent Termination Location Requirements - Vertical.......37
Installation of Support System - PP.............................38
Bracing.................................................................38
Vent System Suppliers............................................38
Long Sweep Elbows...............................................38
Standard long sweep elbow equivalent length material...38
Two Pipe System-Vertical Exhaust/Vertical Air Intake.....39
Two Pipe System-Horizontal Exhaust/Horizontal Air Intake.....41
Two Pipe System-Vertical Exhaust/Horizontal Air Intake..42
Two Pipe System-Vertical/Horizontal Installations.........42
Single Pipe System-Vertical Exhaust /
Room Air Dependent.................................................43
Single Pipe System-Horizontal Exhaust /
Room Air Dependent......................................................43
Single Pipe System-Vertical/Horizontal Installations.......44
Maximum allowable equivalent length -
stainless steel / PP.................................................44
Multiple Boiler Installations.........................................44
Horizontal vent termination.....................................44
Vertical vent termination.........................................44
Two Pipe System-Vertical Exhaust/Vertical Air Intake.....45
Two Pipe System-Horizontal Exhaust/Horizontal Air Intake.....46
Two Pipe System-Vertical Exhaust/Horizontal Air Intake..47
Single Pipe-Vertical Exhaust / Room Air Dependent.......48
Single Pipe-Horizontal Exhaust / Room Air Dependent.......49
Venting
Venting Options - Stainless Steel/PP
Page

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Vitocrossal 200 CM2 Installation Instructions
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
Fiberglass wool and ceramic fiber materials
WARNING
Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are
known to the State of California to cause cancer,
birth defects and other reproductive harm. Always
use proper safety clothing, respirators and equipment
when servicing or working nearby the appliance.
The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.
First aid measures
- If eye contact occurs, flush eyes with water to
remove dust. If symptoms persist, seek medical
attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
Safety
Important Regulatory and Installation Requirements (continued)
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning
Appliances for Canada. For U.S. installations, use the
National Fuel Gas Code ANSI Z223.1. Always use latest
editions of codes.
In Canada all electrical wiring is to be done in accordance
with the latest edition of CSA C22.1 Part 1 and/or local
codes. In the U.S., use the National Electrical Code ANSI/
NFPA 70.
The heating contractor must also comply with
the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1 where
required by the authority having jurisdiction.
Mechanical room
Ensure the mechanical room complies with the
requirements of the System Design Guidelines and/or
Technical Data Manual.
In addition, see section entitled “Mechanical Room” on
page 9 in this manual.
Viessmann recommends installation of an additional
electrical disconnect switch and a fuel shut-off valve (if
possible) outside the mechanical room or enclosed area
of installation.
The maximum room temperature of the mechanical room
where the boiler is located must not exceed 104°F (40°C).
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.
-Eye irritation: If eyes become irritated, flush
immediately with large amounts of lukewarm water
for at least 15 minutes. Eyelids should be held away
from the eyeball to ensure thorough rinsing.
Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and water.
Using a skin cream or lotion after washing may be
helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.

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Vitocrossal 200 CM2 Installation Instructions
Safety
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:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall
horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the
dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be
the responsibility of the property owner to secure the services of qualified licensed professional for the
installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or
an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on
the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector
with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal
for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no
less than one-half (b) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current
edition of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in whole or in part for residential purposes.

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Vitocrossal 200 CM2 Installation Instructions Safety
Important Regulatory and Installation Requirements (continued)
WARNING
Failure to ensure that all flue gases have been safely
vented to the outdoors can cause property damage,
severe personal injury, or loss of life. Flue gases may
contain deadly carbon monoxide.
CAUTION
Under certain climatic conditions some building materials
may be affected by flue products expelled in close
proximity to unprotected surfaces. Sealing or shielding
of the exposed surfaces with a corrosion resistant
material (e.g. aluminum sheeting) may be required to
prevent staining or deterioration. The protective material
should be attached and sealed (if necessary) to the
building before attaching the vent termination. It is
strongly recommended to install the vent termination
on the leeward side of the building.
WARNING
The Vitocrossal 200 is NOT approved for common
venting applications.
Do not attempt to common-vent the boiler with any
other appliance.
For Polypropylene venting systems only
Minimum and maximum wall thickness through which the
horizontal vent-air intake termination may be installed:
Minimum: 1 in. (25.4 mm)
Maximum: 30 in. (762 mm)
Vent-air intake system must be properly installed and sealed.
If PP venting system passes through an unheated space,
such as an attic, it must be insulated.
The insulation must have an R value sufficient to prevent
freezing of the condensate. Armaflex insulation with bin.
thickness and higher can be used.
Venting clearance to combustibles (Stainless Steel /
Polypropylene)
As per vent manufacturer’s requirements.

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Vitocrossal 200 CM2 Installation Instructions
Safety/ General Information
Important Regulatory and Installation Requirements (continued)
Working on the equipment
The installation, adjustment, service, and maintenance of
this boiler must be performed by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water boilers.
There are no user serviceable parts on the boiler, burners,
or control.
Ensure main power supply to equipment, the heating
system, and all external controls has been deactivated.
Close main gas supply valve. Take precautions in all
instances to avoid accidental activation of power during
service work.
Technical literature
Literature for the Vitocrossal 200 CM2 boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instruction
- Instructions of other products utilized and installed
- Installation codes mentioned in this manual and as
locally applicable
The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. This includes low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies.
This product comes with several safety instruction
labels attached. Do not remove!
Contact Viessmann immediately if replacement labels
are required.
About these Installation Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

IMPORTANT
Warnings draw your attention to the presence of
potential hazards or important product information.
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury
or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.

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Vitocrossal 200 CM2 Installation Instructions General Information
Product Information
High efficiency gas-fired hot water condensing boiler.
For operation with modulating boiler water temperatures
in closed loop, forced circulation hot water heating
systems.
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.
The gas burner must always be installed according to
the instructions provided by the burner manufacturer.
The boiler model selected should be based on an accurate
heat loss calculation of the building. The boiler selected
must be compatible with the connected radiation.
The Vitocrossal 200 boiler is suitable for a maximum
operating pressure of 75 psig and a maximum boiler
water temperature of 210°F (99°C).
This boiler does not require a flow switch.
WARNING
Exposing the boiler to pressures and temperatures
in excess of those listed will result in damages, and
will render warranty null and void.
Mechanical Room
The Vitocrossal 200, CM2 boiler should be located in a
heated indoor space. The boiler should also be located
near a floor drain and as close as possible to the vertical
chimney or vent.
Whenever possible, install boiler near an outside wall so
that it is easy to duct fresh air directly to the boiler area.
Install boiler on flooring capable of supporting the weight
of the boiler filled with water.
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.
For Retrofit Applications
Before boiler is connected to piping/heating system,
(which have been previously in service) the piping must
be flushed with city pressure water (50-60 psi) to remove
sludge and other contaminates.
Failure to flush out the heating system piping may result
in restricted flow and/or deposits resulting in boiler failure.
This failure is not covered under warranty.
Do not operate when air is polluted with halogenated
hydrocarbons (e.g. as in aerosols, paints, solvents
and cleaning agents)
Prevent very dusty conditions
Prevent high levels of humidity
Prevent freezing and ensure good ventilation.
Otherwise, the system may suffer faults and damage.

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Vitocrossal 200 CM2 Installation Instructions
Recommended Minimum Service Clearances
Boiler
Legend
ABoiler
BBurner
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. If required,
the boiler door hinge bracket can be reinstalled on the
right side of the door. See burner hinge reinstallation on
page 15.
CM2 186 246 311
a *1 in. (mm) 20 (500) 20 (500) 20 (500)
b *2 in. (mm) 30 (760) 30 (760) 30 (760)
c in. (mm) 20 (500) 20 (500) 20 (500)
d in. (mm) 20 (500) 20 (500) 20 (500)
e in. (mm) 24 (600) 24 (600) 24 (600)
f in. (mm) 22 (550) 22 (550) 22 (55)
g in. (mm) 15b(395) 15b(395) 15b(395)
Minimum clearances to combustibles
Boiler model CM2 186 246 311
Top 0
Sides 0
Flue As per vent manufacturer’s specifications
Front 0
Floor combustible
*1 Clearance may be reduced to zero in multi-boiler
installations, provided the side panel removal is not
required.
Note: The burner, boiler control, condensate trap,
venting and heat exchanger are still fully
accessible from the front and rear of the boiler.
*2 Clearance for vent pipe installation.

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Vitocrossal 200 CM2 Installation Instructions
Preparing the Boiler
Boiler
Flex Hose Air Intake Adaptor
Note: The combustion air intake adapter must be installed
before installing the boiler insulation (whether the
air for the combustion is drawn directly from the
outdoors or a Room Air Dependent combustion
system is used).
1. Attach the flex hose adaptor to the boiler frame using
two M8 bolts, nuts and washers.
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.
A recommended size of the concrete boiler base should
be 50 in. (1250 mm) wide x 31 in. (800 mm) long x 4”
(100 mm) thick for each boiler.
.
1. Remove the wooden shipping block from boiler
base. Remove the 4 leveling bolts A from boiler’s
accessory package and install into boiler base.
Note: When using seismic mounts (optional accessory)
do not install levelling bolts.
2. It is recommended to place a flat piece of steel plate
under each leveling bolt for better weight distribution
and adjustment. Level the boiler, by adjusting the floor
leveling bolts.
3. Remove the wooden block on the boiler doors.
Note: If the boiler is installed even with the ground, install
a condensing drain above the ground max. 2 in.
(50 mm).
WARNING
If flue gas connection is damaged leakage may occur.
Do not lift boiler at the flue gas connection.
Legend
ALeveling bolt
BBoiler end plates (lifting holes)
CBoiler frame
DSeismic mount (optional accessory)
Refer to the Seismic bracket Installation
Instructions when using the optional seismic
mounts.

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Vitocrossal 200 CM2 Installation Instructions
Boiler Insulation
Remove all the components of the boiler jacket from the
shipping box.
1. Wrap around the insulation blanket (black nylon facing
out) and look for boiler’s fitting cutouts.
2. Secure the ends of the blankets with supplied springs.
3. Mount front insulation blanket (If necessary change
the burner door bracket to right hand opening, see
page 15 for details). Secure with springs.
4. Secure the front insulation blanket with supplied
springs.
Boiler Connections
Water Side Connection
Note: Make all connections free of load and torque stresses.
The existing heating system must be properly flushed,
especially if the Vitocrossal 200 boiler is connected to
an existing heating system in a retrofit application.
See page 9 for details.
Connect the system to the boiler according the diagram
on page 13 and 14.
Note: All connections which are not being utilized for
water connections or for controls must be properly
closed.
The supplied air vent and pressure relief valve must be
installed on the top of the boiler - the alternate pressure
relief valve location may be in the boiler supply line. The
piping to the precharged expansion tank, as well as any
automatic feed water required, must be connected to
the boiler drain opening or the safety return connection.
Boiler pump shall be installed on return pipe, pumping
water into the boiler.
The supplied low water cut-off should be installed directly
on top of the boiler or may be installed in the boiler return
piping above the pressure vessel.
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.
Boiler

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Vitocrossal 200 CM2 Installation Instructions
Safety Header
1. Locate safety port on boiler.
2. Install safety header to safety port.
Water pressure: 75 psi (5.2 bar)
Testing pressure: 112 psi (8.2 bar)
Min. water pressure: 8 psi (0.5 bar)
Note: The minimum water pressure is necessary for safe
operation.
Safety valve: All boilers must have a pressure relief valve.
Note: Make all connections free of load and torque stresses.
CAUTION
Do not connect heating system to safety header.
Boiler Connections (continued)
Boiler
Legend
1Boiler return: (ANSI flanges 2bin.) *1
2Boiler supply: (ANSI flanges 2bin.)*1
3Safety port (Safety valve, low water cutoff and
automatic air vent) NPT 1a
ACross 1ain.
BHex bushing 1ain. x ein.
CAir vent with shut-off base
DHex bushing 1ain. x cin.
E90° Street elbow cin.
FNipple cin. x 1 bin.
GPressure relief valve, 75 psi
HLow water cutoff
4Air vent or pressure gauge fem. connection NPT bin.
IHex bushing bin. x ain.
J Pressure gauge
5Drain and fitting for membrane expansion tank NPT 1
6Condensing water drain bin. barb connector
K Tee
L Nipple 1 in. x 2 in.
M Reducer coupling 1 in. x cin.
N Sediment faucet cin.
Thermometer *2 (not shown)
*1Counter flanges (field supplied)
*2 Install anywhere in the supply piping near boiler (not shown)

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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. expansion tank, feed water valve,
pressure relief valve etc.).
2. Remove 75 psig pressure relief valve from the boiler
and cap pipe outlet.
3. Fill boiler with city water and pressurize it to one and
a half (1½) times the maximum working pressure of
boiler. The pressure must be controlled such that it
will never be 10 psig higher than the testing pressure.
Max. allowable working pressure: 75 psig
Testing pressure: 112 psig (do not exceed 122 psig)
4. Monitor pressure over a period of approximately one
hour to ensure that the pressure remains constant and
steady at 112 psig.
5. Should there be a drop in pressure, ensure that all fittings
are secure and tight. Check all flanged connections
with a flashlight.
6. Flue gas collector shall be removed for boiler inspection
should the test water show up in the condensate drain.
7. Open the boiler combustion chamber door and inspect
with a flashlight the front portion of the Inox-Crossal®
heat exchanger sections for system water or fluid.
8. If test is successful, reinstall all hydronic system
components and refill the boiler with water or system
fluid.
WARNING
Never expose the boiler to any pressures higher than
122 psig during testing.
Boiler
Legend
ABoiler supply
BPressure gauge
CPressure relief valve
DBoiler return
EDrain valve
FPrecharged expansion tank
GAutomatic fill
HCondensing water drain

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Vitocrossal 200 CM2 Installation Instructions Boiler
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. Reinstall
per instructions below.
3. Secure the hinges with cotter pins.
4. Tighten the burner body with four M12 bolts and
torque to 13 lb/ft (18 Nm).
Note: If the four burner door bolts do not line up with the
holes on the boiler, loosen the two nuts on hinge
A, align the burner door bolts and tighten again.
WARNING
Flue gas leakage may lead to property damage,
severe personal injury, or loss of life. Flue gas may
contain deadly carbon monoxide.
Legend
ABurner hinge bracket
B Sealing frame
C Burner door seal
Note: If the burner hinge bracket Ais reinstalled please
note that sealing frame Bhas to press on center
of burner door sealing C.
Note: For ease during burner maintenance, route the gas
supply pipe from the opposite side of the burner
hinges.
NPT gas valve connection flange is shipped loose in
burner package.
Install the flange on inlet side of the gas combination valve.
Use supplied O-ring and 4 mm Allen screws.
Tighten with 1.5 lb/ft (2 Nm) torque.
Burner Hinge Reinstallation (if required)
1. Loosen two nuts and remove burner door hinges.
2. Reinstall burner door hinges on the other side of the
boiler. Ensure the stop screw A is at the top of the
door hinge and relocated to the outside hole. Secure
the door hinge with nuts and torque to 37 lb/ft (50 Nm).
Note: Gas line connection is made to the opposite side of
bracket. See page 26 for details.
IMPORTANT
Note: If the burner hinge bracket is reinstalled note that
sealing frame has to press on center of burner door
sealing.

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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. (Be careful not to move mounting rails).
4. Install front control panel (top) and secure with 4.8
metal screws.
Legend
ARating Plate
Combustion Air Flex Hose
1. Install support bracket for flex hose to bottom panel
using two M4 x 10 screws, nuts and washers.
2. Attach the flex hose 76 in. (150 mm) to the flex
hose adaptor and secure the flex hose to the flex hose
adaptor with the retaining clamp.
3. Secure the flex hose to the support bracket with the
retaining clamp.
Note: Do not squeeze hose when securing it with the
retaining clamp.
Boiler

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Vitocrossal 200 CM2 Installation Instructions Boiler
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.
For CM2 boiler model 246 and 311 only
1. Install the combustion air intake adaptor to the burner
air inlet using six M4 x 10 bolts, nuts and washers.
Connect the combustion air flex hose to the burner
flange adaptor and secure with retaining clamp.

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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.
3. Install middle right side panel. Observe aligning
notches and cutouts.
4. Secure middle right panel to top rail with two 4.8
metal screws.
5. Install rear left side panel. Observe aligning notches
and cutouts.
6. Secure rear left panel to top rail with two 4.8 metal
screws.
7. Install middle left side panel. Observe aligning notches
and cutouts.
8. Secure middle left panel to top rail with two 4.8 metal
screws.
Side Panels (front)
1. Insert spring clips Afacing downwards into cut outs
of right and left front side panels.
2. Install right front side panel to bottom rail. Observe
aligning notches and cutouts.
3. Install right front side panel to middle side panel.
Observe clips and cutouts.
4. Install left front side panel to bottom rail. Observe
aligning notches and cutouts.
5. Install left front side panel to middle side panel.
Observe clips and cutouts.
6. Secure both front panels to the top rails with two M5
screws.
Legend
AClips (included in the accessories package).
Boiler

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Vitocrossal 200 CM2 Installation Instructions Boiler
Flue Gas Temperature Switch
Flue temperature switch
Boilers with a polypropylene flue gas collector are supplied
with a flue gas temperature switch, which must be installed.
Boilers with a stainless steel flue gas collector do not have
provisions for a sensor well but may connect an optional
flue gas temperature switch in the venting system.
Contact your venting supplier.
This temperature switch is factory set to 212°F (100°C).
Do Not Adjust.
During the operation of the boiler, should the switch
become activated (open as a safety cut-out), check the
boiler control for a C1 fault on the display. Also check
the flue gas collector and/or vent system for any damage.
The temperature switch can be reset once the
temperature drops approximately 20°F (10°C) from the
factory set point.
Installing the Flue Gas Temperature Switch
Wiring the Flue Gas Temperature Switch
1. Install the sensor well into the flue gas collector and
torque to 44 lb/in (5 Nm).
2. Insert the temperature probe into the sensor well.
Careful not to damage the temperature probe or
capillaries during installation.
3. Insert the support bar into the back of the temperature
switch. Push the temperature switch against the
sensor well and secure the switch to the sensor well
with a screw.
4. Remove the 4 cover screws and the cover.
5. Install the flue pipe adaptor to the flue gas collector
and secure with the supplied gear clamps.
1. Connect the wiring to the switch terminals.
2. Connect the switch box cable connector..
3. Reattach the cover with the 4 screws.
Note: For junction box and control connection see page 21.
IMPORTANT

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Vitocrossal 200 CM2 Installation Instructions
Boiler
Boiler Control and Junction Box
1. Route cables and capillaries from control through the
opening in the control panel. Guide the cables to the
junction box through the opening in the rear panel and
along the top rail to the control. Secure all cables to
the rail with cable ties. Insert temperature probe into
the sensor well.
Note: Never allow cables to come in contact with hot
metal components.
2. Mount the control to the control panel.
3. Secure the control to the control panel with screws.
Note: Screws to secure control are included in
control’s shipping box.
4. Install the junction box to the rear panel either right or
left. Secure the junction box with four 4.8 mm metal
screws.
Note: The ground screw and ground wire can be removed
and then reinstalled with the boiler back panel
attached.
WARNING
Do not bend or kink the capillaries. Damaging the
capillaries leads to malfunction.
Legend
AJunction box
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.