Viessmann VITOCROSSAL 200 Instruction manual

Technical Data Manual
5608 012 v1.1 08/2012
VITOCROSSAL 200
Gas-fired Condensing Boiler
663 to 1112 MBH (194 to 326 kW)
Please file in Service Binder
Model Nos. and pricing : See Price List
Vitocrossal 200
CM2 Series
High efficiency, gas-fired condensing boiler
with pre-mix modulating cylinder burner
for natural gas or liquid propane gas with Inox-Crossal heat
exchanger made of high-grade SA 240-316 Ti stainless steel.
For operation without low limit on boiler return water
temperature.
For closed loop hot water heating systems with maximum
supply water temperatures of 210° F (99° C) for a
maximum operating pressure of 75 psig.
Heating input: 663 to 1112 MBH
(194 to 326 kW)
Product may not be exactly as illustrated.

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Vitocrossal 200
Product Information
Benefits at a glance:
Inox-Crossal heat exchanger surface made of high-
grade SA 240-316 Ti stainless steel for high
operational reliability and long service life.
- Easy dispersal of condensate through vertical gas
flues; therefore no concentration of condensate.
- Increased self-cleaning effect through smooth
stainless steel surfaces.
Highly efficient heat transfer and high condensation
rate through
- heat exchanger surfaces which intensely turbulate
the flue gas flow
- boiler water and hot gases flowing in counterflow.
Efficiency up to 98% through intensive condensation.
The flue gas temperature is only approximately 9 - 27° F
(5 - 15° C) above boiler return temperature (see chart
below).
Clean combustion - through perfect match of burner
and boiler, low combustion chamber loading and
straight-through combustion chamber.
Easy handling in boiler rooms through particularly low
build height and weight.
Easy installation and elimination of wiring mistakes
with Viessmann prewired plug-in system.
Heating boiler, heating system control, domestic
hot water storage tank and all other Viessmann
system technology components are coordinated to
one another.
All components are design-matched for quick
installation.
Pre-mix cylinder burner for environmentally-friendly
operation with a modulation range from 20 to 100%.
All hydronic connections can be fitted from above.
Economical and safe heating system operation
through Vitotronic digital control system with
communication capability. Tailored to every need,
covering all known control strategies and
applications.
Standard LON BUS for complete integration into
building management systems.
Particularly quiet operation.
High altitude operation up to 10,000 ft. (3000 m)
with a simple electronic adjustment.
Vitocrossal 200 boiler efficiency dependent on system
heating water return temperatures and load conditions
Boiler Efficiency in %
System Partial Load in %
Design
Supply / Return
104°F - 88°F
(40°C - 30°C)
Curve 0.5
Design
Supply / Return
167°F - 140°F
(75°C - 60°C)
Curve 1.4
Design
Supply / Return
194°F / 158°F
(90°C - 70°C)
Curve 1.8
Outdoor Temperature
Boiler Water/ Supply Temperature
Room
Set-Point
Temperature

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data Product Information
Cutaway Section
Legend
AInox-Crossal heat exchanger surface made from
high-grade SA 240-316 Ti stainless steel
BHighly effective thermal insulation
CWater cooled stainless steel combustion chamber
DWide water passageways with low pressure drop -
good natural circulation
EFully modulating pre-mix cylinder burner
FVitotronic control unit

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Technical Data
Specifications
Boiler Model CM2 186 246 311
Input MBH 663 878 1112
(kW) (194) (257) (326)
Minimum Input MBH 133 175 222
(kW) (39) (51) (65)
Output*1MBH
(kW)
643
(188)
851
(249)
1078
(316)
Net AHRI rating MBH
(kW)
559
(164)
740
(217)
937
(275)
Combustion efficiency*1% 95 95 95
Thermal efficiency*1% 97 97 97
Overall length(e) in. 73 73 73
(mm) (1852) (1852) (1852)
Overall width (c) in. 36b36b36b
(including insulation) (mm) (930) (930) (930)
Overall height (a) in. 66 66 66
(including control unit) (mm) (1676) (1676) (1676)
Concrete boiler base
Length in. 40 40 40
(mm) (1005) (1005) (1005)
Width in. 31 31 31
(mm) (800) (800) (800)
Thickness in. 4 4 4
(mm) (100) (100) (100)
Weight
Boiler body lb 503 536 564
(Kg) (228) (243) (256)
Complete with the burner, control lb 726 759 792
and thermal insulation (Kg) (329) (344) (359)
Note: For high altitude installations (5,000 to 10,000 ft.), the input will have an altitude de-ration of 15% for 5,000 ft.
and 18% for 10,000 ft.
*1Tested to AHRI, BTS-2000 Testing Standard Method to Determine Efficiency of Commercial Heating Boilers.

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data Specifications
Technical Data (continued)
Boiler Model CM2 186 246 311
Boiler Water Content USG 81 77 74
(L) (306) (292) (279)
Heat exchanger surface ft.273.2 90.4 114.1
water cooled (m2) (6.8) (8.4) (10.6)
Maximum Operating Temperature °F 190 190 190
(°C) (88) (88) (88)
Maximum Operating Pressure psig 75 75 75
(kpa) (517) (517) (517)
Boiler Connections
Boiler supply and return (BS), (BR) in. 2b2b2b
(ANSI flanges) (mm) (65) (65) (65)
Safety Supply in. 1a1a1a
(mm) (32) (32) (32)
Boiler Drain in. 1 1 1
Condensate Drain in. ccc
Vent pipe
Internal Diameter in. 8 8 8
(mm) (201) (201) (201)
Flue Gas Values
temperature (at a return
temperature of 86° F (30° C)
at rated input °F 136 132 130
(°C) (58) (55) (54)
at partial load °F 95 95 95
(°C) (35) (35) (35)
Temperature (at a return
temperature of 140° F (60° C)
at rated input °F 167 167 167
(°C) (75) (75) (75)
Mass flow rate (of flue gas)
at rated input lbs/h 593 785 994
(kg/h) (269) (356) (451)
at partial load lbs/h 198 262 331
(kg/h) (90) (119) (150)
Pressure
at boiler flue outlet pa 70 70 70
at rated input “w.c. 0.28 0.28 0.28

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Dimensions
Specifications
Legend
V Vent pipe connection
D Drain
CD Condensate drain
BR Boiler return
BTS Boiler water temperature sensor
BS Boiler supply
SH Female connection NPT bin. for pressure gage
CA Combustion air pipe connection
SS Safety supply; pressure relief valve, air vent,
low water cut-off
Dimensions
Model CM2 186 246 311
a in. (mm) 66 (1676) 66 (1676) 66 (1676)
b in. (mm) 56b(1438) 56b(1438) 56b(1438)
c in. (mm) 36b(930) 36b(930) 36b(930)
d in. (mm) 30 (760) 30 (760) 30 (760)
e in. (mm) 73 (1852) 73 (1852) 73 (1852)
f (flue pipe projection at the back) in. (mm) 3 (75) 3 (75) 3 (75)
g in. (mm) 59 (1500) 59 (1500) 59 (1500)
h (foot length) in. (mm) 39b(1005) 39b(1005) 39b(1005)
i (distance from front face of the cover to the front
supporting foot)
in. (mm) 12c(323) 12c(323) 12c(323)
k in. (mm) 53c(1365) 53c(1365) 53c(1365)
l (distance from the front face of the cover to
the centre of the the boiler supply connection)
in. (mm) 28c(729) 28c(729) 28c(729)
m in. (mm) 10c(275) 10c(275) 10c(275)
n in. (mm) 10 (255) 10 (255) 10 (255)
o in. (mm) 11a(284) 11a(284 11a(284
p in. (mm) 58c(1493) 58c(1493) 58c(1493)
q in. (mm) 22 (558) 22 (558) 22 (558)
r in. (mm) 5b(142) 5b(142) 5b(142)
s in. (mm) 5 (126) 5 (126) 5 (126)
t in. (mm) 4 (100) 4 (100) 4 (100)
u in. (mm) 8 (207) 8 (207) 8 (207)
v in. (mm) 4 (100) 4 (100) 4 (100)

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data Specifications
Recommended Minimum Service Clearances
Mechanical room
Avoid air contamination by halogenated hydrocarbons
(e.g. as in sprays, paints, solvents and cleaning agents)
Avoid very dusty conditions
Avoid high levels of humidity
Protect against frost and ensure good ventilation,
otherwise the system may suffer faults and damage.
In rooms where air contamination from halogenated
hydrocarbons is to be expected, operate the boiler
only in balanced flue mode.
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
Legend
ABoiler
BBurner
*1 Can be zero clearance, if serviceability and burner
swing position is not required.
*2 Clearance for vent pipe installation.
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.
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) 11 (280) 11 (280) 11 (280)
g in. (mm) 15b(395) 15b(395) 15b(395)

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Flow Rate
Specifications
Pressure drop (primary circuit)
The Vitocrossal 200 is only suitable for fully pumped hot
water heating systems.
Recommended Flow Rates CM2
Boiler model 186 246 311
20° F rtGPM 63 84 106
40° F rtGPM 31 42 53
11° C rtm3/h 14.3 19.07 24.07
22° C rtm3/h 7.04 9.53 12.04
rt = temperature difference
This boiler does not require a flow switch.
“w.c. mbar
m3/h
GPM
Pressure drop
Flow rate

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Cylinder Burner
Specifications
Boiler Model CM2 186 246 311
Product ID see boiler
Voltage V 120 120 120
Frequency Hz 60 60 60
Power consumption
at max. input W 225 278 368
at min. input W 51 52 67
Version modulating
Dimensions
Length in. (mm) 30.3 (770) 30.3 (770) 30.3 (770)
Width in. (mm) 21.5 (546) 21.5 (546) 21.5 (546)
Height in. (mm) 18.9 (482) 18.9 (482) 18.9 (482)
Weight
Burner only
Burner package (with kits, flanges and
mounting hardware)
lb. (kg)
lb. (kg)
61.0 (27.6)
93 (42.2)
64.5 (29.3)
100.5 (45.5)
64.5 (29.3)
100.5 (45.5)
Min. gas supply pressure
Natural gas “w.c. 4 4 4
Liquid propane gas “w.c. 10 10 10
Max. gas supply pressure
Natural gas “w.c. 14 14 14
Liquid propane gas “w.c. 14 14 14
Gas connection NPT 1 1a1a
Specifications

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Cylinder Radiant Burner (continued)
Specifications
CM2 pre-mix cylinder burner 186/246/311
Legend
ABoiler door
BAir pressure switch 1
CFan
DBurner display and programming unit
EGas valve with gas pressure switch
FGas supply pipe
GBurner test firing valve
HCylinder burner assembly
IIgnition electrodes
Note: Solenoid valve (choke valve) for CM2 model 186
(not shown).
JIonization electrode
KGas pipe
LAC-EMI suppresion filter device
MIgnition unit
NThermal insulation block
OManual shut-off valve
PVenturi mixing pipe
QAir pressure switch 2
RBurner control sub-base
SServomotor and burner inlet damper (for models 246 / 311)

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
Standard Equipment
Installation fittings for standard equipment includes:
- low water cut-off
- safety header (c/w 75 psig pressure relief valve,
air vent and pressure gage)
- drain valve
- product documentation
- combustion air intake kit
- NG to LPG conversion kit
For multi-boiler system (up to 4 boilers)
without Vitocontrol control panel
Vitotronic 100 (type GC1) and LON module
for modulating boiler water temperature in
conjunction with an external control unit (BMS).
with Vitocontrol control panel
Vitotronic 100 (type GC1) and LON module
for modulating boiler water temperature for each
boiler of the multi-boiler system and
Vitocontrol-S, CM2 control panel
with Vitotronic (300K MW1) for multi-boiler system,
outdoor reset mode and mixing valve control for a
maximum of 2 heating circuits with mixing valve and
additional Vitotronic 050, type HK1S or HK3S for 1
or up to 3 heating circuits with mixing valve.
For single-boiler or multiple-boiler installations
Custom control panels for residential or commercial
applications are designed and manufactured by Viessmann
to suit any customer’s specific requirements. Custom
control panels can have features such as pool heating,
hot tub heating, snow melting, telephone tie-in, integration
with Building Management Systems, as well as several
other functions. Please inquire.
For single boiler systems
without Vitocontrol control panel
Vitotronic 100 (type GC1)
for constant boiler water temperature or outdoor reset
mode in conjunction with an external control unit (BMS).
Vitotronic 300 (type GW2)
for modulating boiler water temperature with mixing
valve control for a maximum of two heating circuits
with mixing valve.
with Vitocontrol control panel
Vitotronic 100 (type GC1)
and
Vitocontrol-C, CM2 control panel
with Vitotronic (300 MW1S) for outdoor reset mode
and mixing valve control for a maximum of 2 heating
circuits with mixing valve and additional Vitotronic
050, type HK1S or HK3S for 1 or up to 3 heating
circuits with mixing valve.
Boiler Control Alternatives
Specifications
1 thermal insulation
1 cylinder burner
1 boiler control unit (see boiler control alternatives below)
1 boiler coding card
1 technical documentation
Boiler body with fitted mating ANSI flanges and gaskets
to all connectors and fitted protective crate, plus flue gas
collector collar.

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
System Design Considerations
Note: The ‘amount of condensate” and the “flue gas
temperature gross” graphs are independent of each
other.
Condensate and its disposal
During the operation of the boiler, the amount of
condensate to be expected can be read from the above
diagram.
The values given are approximate amounts occurring
under practical conditions. Not included in the diagram
is the amount of condensate occurring in the vent pipe
and chimney system. The condensate from the chimney
system can be collected together with the condensate
from the heating boiler and be disposed of into a floor
drain. The condensate will be between 3 and 4 on the pH
scale. If local building requirements demand neutralizing
the condensate before disposal, contact Viessmann
Manufacturing Company Inc. for a correctly sized
neutralization tank. The treated condensate will show
pH values of between 6.5 and 9 and can then be
disposed of into the waste water system.
Design notes regarding draining condensate
The condensate drain to the sewer connection must be
able to be inspected.
Route it with a gradient and equip the pipe with a P-trap;
also provide suitable facilities for taking samples.
The bottom drain should be located below the anti-flooding
level of the flue gas collector box.
Condensate drains must only be made from corrosion
resistant materials (e.g. fibre reinforced hoses). Never use
any galvanized materials or those containing copper or
black iron for pipes, connectors, etc.
Install a P-trap in the condensate drain to prevent flue
gases from escaping.
Specifications
Venting options
PP(s) (Polypropylene) flue gas/fresh air system for room
air independent operation (sealed combustion), and PP(s)
flue gas for room air dependent operation are tested
to ANSI Z21.13 - CSA 4.9 - 2000 standards and are
certified together with the Vitocrossal 200 boiler as a
constructional unit.
The Vitocrossal 200 boiler may also be vented using an
special stainless steel, single-wall, (UL listed for category IV).
The boiler may be vented horizontally through the side
wall or vertically through the roof.
For a more detailed description of the direct vent and
single-wall vent system, please refer to the Vitocrossal
200 Installation Instructions venting section.
Use ULC S-636 / UL 1738 certified for category IV
boilers. The following vent system suppliers may be
contacted for assistance in designing the appropriate
PP(s) venting system for Vitocrossal 200 CM2 boilers.
M&G / Duravent
Tel. [phone]
Tel. [phone]
Fax: [phone]
Email: [email protected]
Web: www.duravent.com
Centrotherm InnoFlue
Eco Systems. L.L.C.
Tel. [phone]
Fax. [phone]
Email: [email protected]
Web: www.centrotherm.us.com
Amount of condensate
Boiler water return temperature
Flue gas temperature gross
Flue gas temp.
at full input
at partial load
Flue gas temp.
Amount of
condensate
Ensure that the domestic drainage systems are made
from materials which are resistant to acidic condensate
such as:
Stoneware pipes
Hard PVC pipes
PVC pipes
PE-HD pipes
PP(s) pipes
ABS/ASA pipes
Stainless steel pipes
Borosilicate pipes

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
System Design Considerations (continued)
M&G / Duravent
Tel. [phone]
Tel. [phone]
Fax: [phone]
Email: [email protected]
Web: www.duravent.com
Selkirk Canada Corporation
375 Green Road
Stoney Creek, ON L8E 4A5
Tel.: [phone]
Fax: [phone]
(US) 1-800-992-8368
(Canada) 1-888-735-5475
Email: [e-mail]
Web: www.selkirkchimney.com
Van-Packer Co. Inc.
302 Mill Street
PO Box 307
Buda, IL 61314
Tel.: [phone]
Fax: [phone]
1-888-877-8225
Email: [e-mail]
Web:www.vpstack.com
Enervex Inc. (formerly Exhausto)
Tel: [phone]
Fax: [phone]
[phone]
Email: [e-mail]
Web:www.vpstack.com
Wesmech Technical Sales
50 Ronson Drive, Suite 160
Toronto, ON M9W 1B3
Tel.: [phone]
Fax: [phone]
1-800-613-3789
Email: [e-mail]
Web: www.wesmechtech.com
Security Chimneys International Ltd.
2125 Rue Monterey, Laval, Quebec H7L 3T6
Tel. [phone]
(US) 1-800-361-4909
(Canada) 1-800-667-3387
Fax: [phone]
Email: [email protected]
Web: www.securitychimneys.com
Specifications
System layout
The boiler water temperature limit is factory set to
167° F (75° C).
The boiler water temperature limit can be increased by
altering the adjustable high limit (AHL) to increase the
supply water temperature.
To minimize piping losses of the system, however,
Viessmann recommends that the radiation and domestic
hot water production in the system be designed for a
158° F (70° C) boiler supply water temperature.
Warranty
Our warranty does not cover damages resulting from
the following:
- Operation with contaminated fill and supplementary
feed water
- Operation with contaminated combustion air
- Exposing the boiler to pressures and temperatures
higher than its certified rating
See warranty sheet for details.
Use ULC S-636 / UL 1738 certified for category IV
boilers. The following vent system suppliers may be
contacted for assistance in designing the appropriate
stainless steel venting system for Vitocrossal 200 CM2
boilers.
Combustion air supply
The boiler must not be located in areas or rooms where
chemicals containing chlorine, bromine, fluorine, or other
corrosive chemicals are stored. Examples include bleach,
refrigerants, paint, paint thinner, hair spray, cleaning
solvents, water softener salt, etc. The combustion air
must not be contaminated with any amount of the above
mentioned chemicals.
Boiler should never be installed in areas where excessive
dust, high humidity, or risk of frost exist. Ensure adequate
ventilation and supply of fresh combustion air.
Consult your local Viessmann sales representative with
uncertainties in regard to a suitable boiler installation
location.
This boiler/burner unit needs clean fresh air for safe
operation. Provisions for combustion and ventilation air
must be made at time of installation. For gas or propane
installations, use the “Natural Gas Installation Code CAN/
CSA-B149.1 or B149.2” (Canada), or “National Fuel Gas
Code ANSI Z223.1” (USA), and/or provisions of local codes.
The sizing methods outlined in the aforementioned codes
should be used when installing a round duct to supply
combustion air from the outside.

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data
System Design Considerations (continued)
Airborne noise attenuation
Frequently, modern boilers are equipped with silencer hoods
or sound insulated ventilation air inlet housings.
For larger systems, it may be necessary to route the
ventilation air through a sound-insulated channel, in order
to avoid a noise nuisance outside the building.
Flue gas silencers are generally only required where higher
noise protection measures are called for. Whether or not
a flue gas silencer is required can be predicted only with
some difficulties, because of the complexity of the creation
and propagation of flame noise, the interaction between
the burner, boiler and the flue gas system as well as the
operating mode (flue gas system operating with positive
or negative pressure).
It is advisable, therefore, to assess the noise emission into
the neighborhood and to consider the sound pressure level
measured at the flue gas system outlet. It should be
considered at the planning stage whether silencers might
become necessary later.
In planning for its possible use, it is important that
sufficient space for the flue gas silencer is available behind
the boiler. Good engineering practice mandates that the
exhaust pressure drop of the silencer be included in the
vent size calculation.
Anti-vibration measures
Anti-vibration supports can be field supplied as an
economical and effective solution to combat noise
generated.
When sizing such supports, take the entire operating
weight of the boiler system and, when using longitudinal
anti-vibration brackets, the condition of the supporting
surface into consideration.
Effective anti-vibration measures are particularly important
when installing boilers into an attic. Flexible couplings
may be used to physically separate the combustion
equipment from the building.
These should be installed into the boiler flow, return and
safety pipe and as near as possible to the boiler.
Also insulate any braces or hanging arrangements, if
installed, against sound/vibration transmission to the
building.
Specifications
Water quality
Treatment for boiler feed water should be considered
in areas with known problems, such as where a high
mineral content and hardness exist. In areas where
freezing might occur, it recommended that an antifreeze
be added to the system water for protection against
freezing. Please adhere to the specifications given by the
antifreeze manufacturer. Do not use automotive silicate-
based antifreeze. Please observe that an antifreeze/water
mixture may require a back flow preventer within the
automatic water feed and influence components such
as diaphragm expansion tanks, radiation, etc. A 40%
antifreeze content will provide freeze-up
protection to -10° F (-23° C). Do not exceed 50%
antifreeze mix ratio and do not use antifreeze other than
specifically made for hot water heating systems.
Oxygen diffusion barrier under floor tubing
The boiler warranty does not cover pressure vessel failure
resulting from corrosion caused by the use of underfloor
plastic tubing without an oxygen diffusion barrier. Such
systems without oxygen diffusion barrier must have the
tubing separated from the boiler with a heat exchanger.
Viessmann always recommends the use of underfloor
plastic tubing with an oxygen diffusion barrier.
Boiler/burner start-up
Vitocrossal 200, CM2 boilers with Viessmann cylinder
burners does not require start-up by Viessmann.
Sound attenuation
Please consult a professional engineer who is specialized
in noise attenuation for advice.
The burner/boiler systems, circulation pumps and other
auxiliary equipment used in heating systems generate
noise.
This noise is transferred from the boiler room via
floorboards, ceiling and walls to neighboring rooms and
via the flue gas system as well as the ventilation air and
exhaust air apertures into other rooms and into the open,
where they may cause a nuisance.
To avoid this from happening, additional protective
measures may be required which should be considered
at the design stage.
Subsequent measures to reduce noise nuisance frequently
require extensive effort and expenditure.
Total output (MBH) Total Hardness (ppm as ca CO3)
> 1 Total [ 680 [ 200
> 680 to [ 255 [ 150
The pH value of the heating water should be between 8.2
and 9.5

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5608 012 v1.1
Vitocrossal 200 CM2 Technical Data

16
5608 012 v1.0 Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.