Viessmann VITOCROSSAL 200 User manual

Installation Instructions
VITOCROSSAL 200
5773 597 - 04 09/2014
for use by heating contractor
Vitocrossal 200
CM2 Series 400, 500 and 620
Gas condensing boiler with cylinder burner
Read and save these instructions
for future reference.
Please file in Service Binder
Heating input: 1445 to 2245 MBH
(423 to 658 kW)
Product may not be exactly as shown
IMPORTANT
H

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Vitocrossal 200, CM2 400, 500 and 620 Installation
Safety, Installation and Warranty Requirements
Safety
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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Safety, Installation and Warranty Requirements
Safety
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.
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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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
Fiberglass wool and ceramic fiber material..................3
First aid measures....................................................3
Codes.....................................................................3
Mechanical room.....................................................3
Important Regulatory and Installation Requirements........6
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.......................................7
Technical literature..................................................7
About these Installation Instructions..............................8
Product Information....................................................8
Mechanical Room.......................................................9
For Retrofit Applications..............................................9
Recommended Minimum Service Clearances. ...............10
Preparing the Boiler...................................................11
Boiler Insulation........................................................12
Boiler Door Insulation................................................12
Boiler Door..............................................................13
Combustion Air Flex Hose.........................................14
Flex Hose Air Intake Adaptor......................................14
Boiler Connections....................................................14
Water side connection...........................................15
Safety Header.......................................................16
Hydrostatic Test Procedure........................................17
Rails and Supports....................................................18
SidePanels.................................................................18
Cross Bar...............................................................19
Mounting the Burner..................................................19
Combustion Air Adapter Burner Connection..................20
Front Side Panels......................................................21
Bottom Plate...........................................................21
Electrical Connections................................................22
System Power Supply................................................22
Routing Cables.........................................................23
Boiler Water Temperature Sensor................................24
Flue Gas Temperature Sensor.....................................24
Condensate Connection.............................................25
Rear Panels..............................................................27
Boiler Control and Junction Box..................................27
Top Panels...............................................................28
Front Panels.............................................................28
Control Panel and Covers...........................................29
Gas Flue Connections................................................29
GasConnections.........................................................30
Valve leak test......................................................31
Boiler Piping in Heating / Cooling Application................32
Initial System Fill......................................................33
Introduction
Safety
General Information
Boiler
Page

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General Venting Information......................................34
Installation steps (outline).......................................34
Recommended venting practice...............................34
Approved venting materials.....................................35
Vent termination location requirements
(for installations in Canada).....................................36
Vent termination location requirements
(for installations in the U.S.A.)..................................36
Flashing and storm collar installation...........................37
Additional Requirements for Stainless Steel
Vent Pipe Material.....................................................37
Exhaust vent/air intake connection to boiler..............37
Requirement for UL/ULC listed Rigid PP
Vent Pipe Material...................................................38
Requirements for PP and stainless steel....................38
Vent system suppliers............................................38
VentRequirements..................................................39
Combustion air supply, room air dependant
application only.....................................................39
Direct Venting (Two Pipe System)...............................40
Side wall vent termination [stainless steel, CPVC or PP]...40
Side Wall Venting....................................................41
Side wall vent termination [stainless steel or PP]........41
Component Installation Guide.....................................42
Flashing and storm collar installation........................42
Vent Termination Location Requirements - Vertical.......42
Installation of Support System - PP.............................43
Bracing.................................................................43
Vent system suppliers............................................43
Long Sweep Elbows...............................................43
Standard long sweep elbow equivalent length material...43
Two Pipe System-Vertical Exhaust/Vertical Air Intake.....44
Two Pipe System-Horizontal Exhaust/Horizontal Air Intake.....44
Two Pipe System-Vertical Exhaust/Horizontal Air Intake..45
Two Pipe System-Vertical/Horizontal Installations.........45
Single Pipe-Vertical Exhaust / Room Air Dependent.......46
Single Pipe-Horizontal Exhaust / Room Air Dependent.......46
Single Pipe System-Vertical/Horizontal Installations.......47
Maximum allowable equivalent length -
stainless steel / PP.................................................47
Multiple Boiler Installations.........................................47
Horizontal vent termination.....................................47
Vertical vent termination.........................................47
Venting
Venting Options - Stainless Steel/PP
Page

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Important Regulatory and Installation Requirements
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 gasfitter 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 gasfitter 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.
General Information

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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.
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.
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.
Note: 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.
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
Note: 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.
General Information

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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.
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.
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.
General Information

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Vitocrossal 200, CM2 400, 500 and 620 Installation General Information
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 400, 500 and 620 Installation
Recommended Minimum Service Clearances
Boiler
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.
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.
Minimum clearances to combustibles
Boiler model CM2 400 500 620
Top 0
Sides 0
Flue As per vent manufacturer’s specifications
Front 0
Floor combustible
Legend
ABoiler
BBurner
*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.
CM2 400 500 620
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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Preparing the Boiler
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.
Boiler
Legend
ALeveling bolt
BBoiler end plates (lifting holes)
CBoiler frame
DSeismic mount (optional accessory)
Note: To install lifting straps, use the lifting holes in the
boiler end plates B.
Refer to the Seismic bracket Installation
Instructions when using the optional seismic
mounts.

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Vitocrossal 200, CM2 400, 500 and 620 Installation
Remove all the components of the boiler jacket from the
shipping box.
1. Wrap around the insulation blanket A(black nylon
facing out) and look for boiler’s fitting cutouts.
2. Secure with spring clips.
The insulation blanket is not reversible. Ensure the correct
orientation prior to installation.
Boiler
Boiler Insulation
Boiler Door Insulation
1. Remove six boiler door bolts and set aside.
2. Swing the boiler door open.
3. Apply the boiler door insulation.
CAUTION
The boiler door can cause damage and personal injury
if it swings shut. After opening the boiler door take
measures to prevent it from swinging shut.
IMPORTANT

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Vitocrossal 200, CM2 400, 500 and 620 Installation
Boiler Door (continued)
Converting the boiler door
1. To convert the boiler door to the opposite side
move hinge pin Ato the RH side.
Note: Ensure that sealing frame Bpresses onto the
centre of gasket Din the boiler opening. It may
be necessary to align mounting brackets C.
Legend
ADoor hinge pin
BBoiler door gasket frame
CAligning bracket
DBoiler door gasket
Boiler

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Vitocrossal 200, CM2 400, 500 and 620 Installation
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. Place the flex hose adaptor to the boiler frame
bracket.
2. Attach using two M8 bolts, nuts and washers.
1. Attach the flex hose 78 in. (200 mm) to the flex
hose adaptor and secure the flex hose to the flex
hose adaptor with the retaining clamp.
2. Secure the flex hose to the support bracket with
the retaining clamp.
Note: Do not squeeze hose when securing it with
the retaining clamp.
Combustion Air Flex Hose

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Vitocrossal 200, CM2 400, 500 and 620 Installation
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 16.
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 400, 500 and 620 Installation
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.
* Counter flanges ANSI 4” gaskets and hardware (field
supplied)
CAUTION
Do not connect heating system to safety header.
Boiler Connections (continued)
Legend
1Boiler return: (ANSI 4 in.)*
2Boiler supply: (ANSI 4 in.)*
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 1 in.
FNipple 1 in. x 2 in.
GPressure relief valve, 75 psi
HLow water cutoff
4Pressure gauge fem. connection NPT bin.
IHex bushing bin. x ain.
J Pressure gauge
5Drain and fitting for membrane expansion tank
6Condensing water drain NPT bin.
K Tee 1b in x 1bin. x cin.
L Sediment faucet cin.
M Hex bushing 1ain. x 1 in.
7 Gas line fittings
N Nipple, 1ain. x 2b in.
O 90° Elbow, 1ain.
P Gas ball valve, 1ain.
Q Reduction tee 1b in x 1bin. x cin.
Boiler

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Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler
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.
Legend
ABoiler supply
BPressure gauge
CPressure relief valve
DBoiler return
EDrain valve
FPrecharged expansion tank
GAutomatic fill
HCondensing water drain

18
5773 597 - 04
Vitocrossal 200, CM2 400, 500 and 620 Installation
Rails and Supports
1. Insert four M6 x 10 screws halfway into each side
of the top and base frame.
2. Hook the top LH and RH rails onto the top frame
using the keyholes.
3. Hook the bottom LH and RH rails onto the base
frame, so that the rails protrude to the rear.
4. Make sure the top rails are aligned at the front
(see A). Then tighten all screws to secure each rail.
5. Install bottom plate brackets using two M6x15 screws
per bracket. Pre fit the side and top panels to allow
for rail alignment. Once rails are aligned, remove the
side and top panels and tighten screws (see pages 18
and 27 for panel installation).
Legend
A Rail alignment
B Rails on top frame
C Rails on base frame
DBody supports (included with the boiler)
Boiler
Side Panels
Legend
ASide panel, front
BSide panel, centre
CRH rear side panel
Note: Adjust the side panels to line up with the front
panel A before securing with screws.
1. Install left center side panel E. Observe aligning
notches and cutouts.
2. Install right center side panel B. Observe aligning
notches and cutouts.
3. Install right front side panel A. Observe aligning
notches and cutouts.
4. Install left front side panel F. Observe aligning
notches and cutouts.
5. Install rear left side panel D. Observe aligning
notches and cutouts.
6. Install right rear side panel C. Observe aligning
notches and cutouts.
7. Secure side panels to the top rails with two 2.8 mm
screws per panel.
DLH rear side panel
ESide panel, centre
FSide panel, front

19
5773 597 - 04
Vitocrossal 200, CM2 400, 500 and 620 Installation Boiler
Cross Bar
1. Install the cross bar (using the rear holes) to the top
rail with two screws.
Mounting the Burner
1. Insert six M12 threaded studs into the boiler door.
2. Put gasket in place.
3. Position the burner at the boiler door, guiding the
burner gauze assembly carefully through the opening.
Note: Do not remove the burner gauze assembly
protection during the installation to the boiler
door. Ensure that the burner gauze assembly
is kept free from the thermal insulation block
fibres.
Note: The burner should be fitted by two people
or with the use of a lifting aid. Take care not
to damage the electrodes and burner gauze
assembly.
4. Tighten the six nuts M12 diagonally and torque
to a minimum of 13 lb/ft (18 Nm).
Note: All parts required for installing the burner are
contained in the burner carton.
5. Open the boiler door and carefully remove the burner
gauze assembly protection.
6. Close boiler door and tighten the six bolts M12
diagonally. Torque to 29.5 lb/ft (40 Nm).
CAUTION
Faults may occur if the burner gauze assembly is
contaminated or incorrectly installed. Ensure that the
combustion chamber and the burner gauze assembly
are kept free from the thermal insulation block fibres.
Refer to the Service Instructions when checking
for electrode gap or burner gauze damage.

20
5773 597 - 04
Vitocrossal 200, CM2 400, 500 and 620 Installation
Combustion Air Adapter Burner Connection
1. Secure intake connector with hex head screws,
washers and nuts to the flange of the
rotary damper.
2. Secure ventilation air hose DN 200 with hose clip
7 8 in. (7200 mm) on the intake connector.
Boiler