Viessmann CM2 500 Installation Instructions Manual Download Page 1

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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

Summary of Contents for CM2 500

Page 1: ...ting 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 ...

Page 2: ...ated 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 syst...

Page 3: ...lation 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 th...

Page 4: ...ical 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 Combus...

Page 5: ...ation 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 ...

Page 6: ...ired 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...

Page 7: ...sed 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...

Page 8: ...res 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 acco...

Page 9: ...stall 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...

Page 10: ...d 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 A Boiler B Burner 1 Clearance may be reduced to zero in mul...

Page 11: ...ing 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...

Page 12: ...cure 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 ...

Page 13: ...To convert the boiler door to the opposite side move hinge pin A to the RH side Note Ensure that sealing frame B presses onto the centre of gasket D in the boiler opening It may be necessary to align mounting brackets C Legend A Door hinge pin B Boiler door gasket frame C Aligning bracket D Boiler door gasket Boiler ...

Page 14: ...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 7 8 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 ...

Page 15: ...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 shoul...

Page 16: ...y header Boiler Connections continued Legend 1 Boiler return ANSI 4 in 2 Boiler supply ANSI 4 in 3 Safety port Safety valve low water cutoff and automatic air vent NPT 1a A Cross 1a in B Hex bushing 1a in x e in C Air vent with shut off base D Hex bushing 1a in x c in E 90 Street elbow 1 in F Nipple 1 in x 2 in G Pressure relief valve 75 psi H Low water cutoff 4 Pressure gauge fem connection NPT b...

Page 17: ...g 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 i...

Page 18: ...installation Legend A Rail alignment B Rails on top frame C Rails on base frame D Body supports included with the boiler Boiler Side Panels Legend A Side panel front B Side panel centre C RH 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 pan...

Page 19: ...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 t...

Page 20: ... 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 7 200 mm on the intake connector Boiler ...

Page 21: ...site side of the burner hinges otherwise the panel cannot be removed when swinging burner left or right See page 13 2 Fit two clips A per side panel included in the accessory pack 3 Using the clips hook front side panels C and D into side panels E and F 4 Loosely secure front side panels C and D to the top rails with one screw M6 x 10 per panel 5 After hooking in the side panels align supports B a...

Page 22: ... page 23 3A 3B Boiler water temperature sensor 15A 15B Flue gas temperature sensor 40 Power cable to junction box 40 156 Vitotronic power supply 41 Burner cable to Vitotronic control 53 Rotary vent damper connection optional accessory not used 145 KM BUS cable to Vitotronic control Note Never allow cables or leads to come into contact with hot components Secure all cables and leads with cable ties...

Page 23: ...ote Route 120V cables F and low voltage leads separately Route along the top rail A in a bundle using plug in cable retainers Route beneath the top B rail in a bundle using plug in cable retainers Route to the sensor well C above the thermal insulation without looping the lead Secure with a clamp For installation of the sensor see page 24 Route to the flue gas collector E Note Insert the boiler wa...

Page 24: ...to the burner electrical connector 1 Remove the screws the cable strap and connector cover from the flue gas collector and set aside 2 Route the flue gas temperature sensor cable along the channel in the flue gas collector 3 Connect the individual cable connectors to the flue gas collector 15A and 15B sensor connectors 4 Install the cable strap and connector cover with screws and tighten 5 Install...

Page 25: ...4 Vitocrossal 200 CM2 400 500 and 620 Installation Boiler Condensate Connection 1 Fill the siphon with water and attach to boiler Legend A Condensate drain IMPORTANT The condensate drain must be able to be inspected ...

Page 26: ...s installed even with the ground install a condensing drain above the ground max 2 in 50 mm Note The amount of condensate and the flue gas temperature gross graphs are independent of each other Amount of condensate Boiler water return temperature F lue gas temperature gross Flue gas temp at full input at partial load Flue gas temp A m o u n t o f c o n d e n s a t e The Vitocrossal CM2 boiler come...

Page 27: ...ol 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 3 Mount the control to the control panel 4 Secure the control to the control panel with screws Note Screws to secure control are included in control s shipping box Legend A Junction box Rear Panels 1 Install rear lower panel and secure ...

Page 28: ...they overlap in the middle secure both rear top panels to the central top panel with one 4 8 mm x 38 mm screw 5 Secure RH rear top panel E and LH rear top panel D to the back panel with one 4 8 mm screw each Front Panels 1 Attach four clips E included with the fixings to the bottom front panel 2 Hook bottom front panel C into the front side panels 3 Screw two profile studs B into top front panel D...

Page 29: ...d and torque stresses The venting system must be securely supported by an anchoring system as outlined by the venting manufacturer IMPORTANT The boiler flue gas collector vent is not designed to support the weight of the venting system Control Panel and Covers 1 Plug in control interface cable and install cover 2 Install control cosmetic cover 3 Install buffer panel to the top rail and secure with...

Page 30: ...rge gas line in a safe manner using an approved purge burner WARNING If test pressure is too high burner and gas fittings may get damaged WARNING Escaped gas may lead to explosion which could cause severe injuries Do not vent gas pipe above combustion chamber of boiler Legend A O ring groove B O ring C Gas valve flange D Mounting bolts E Pressure measurement port CAUTION If gas pipe contains dirt ...

Page 31: ...fy shutoff valves as such with a tab and familiarize operator ultimate owner of boiler with these valves See Vitocrossal 200 CM2 Series 400 to 620 Service Instructions for applicable system coding information Legend A Manual test firing valve B Gas Valve C O ring D Gas valve flange E Mounting nuts F Nipple G Elbow H Nipple I Manual gas shutoff valve J Nipple field supplied K Ground joint union rec...

Page 32: ...the heating coils located in the air handling units The boiler piping system may be exposed to refrigerated air circulation and must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Check the installation instructions of the chiller manufacturer carefully for additional requirements Cooling season starts Close...

Page 33: ...d to the top of the boiler or the safety supply of the boiler see page 15 No valve shut off device or obstruction of any kind and no construction must be used between boiler and relief valve or on the discharge side of the pressure relief valve The discharge side of the pressure relief valve must continue in the same size as the outlet horizontally over the side of the boiler and then vertically d...

Page 34: ...e the joint ends of the vent pipe collar and if used the air intake pipe collar Slide pipes into each other with a gentle twisting motion Condensate must drain from the flue pipe to the boiler Ensure a suitable gradient of at least 3º approx 2 in per 3 3 ft 50 mm per 1 m Use a hacksaw or sheet metal snips for stainless steel to cut pipes to length if necessary Use a file to smooth rough edges Pipe...

Page 35: ...665 D1785 CSA B137 3 B181 2 ANSI ASTM F441 CPVC Schedule 40 ANSI ASTM D2661 CSA B181 1 ULC S102 2 ANSI ASTM D2665 D1785 CSA B137 3 B181 2 ANSI ASTM F441 ABS DWV Schedule 40 ANSI ASTM D2661 CSA B181 1 ULC S102 2 ANSI ASTM D2665 D1785 CSA B137 3 B181 2 ANSI ASTM F441 PP Polypropelene UL1738 Venting systems for gas burning appliances Categories II III IV ULC S636 Standard for Type BH gas venting syst...

Page 36: ...n 3 ft 0 9 m to the property line advisable not mandatory please check with local building authorities and municipal bylaws 11 at a location where ice formation on the ground can present a hazard 12 so that the flue gases are directed toward brickwork siding or other construction in such a manner that may cause damage from heat or condensate from the flue gases 13 where discharging hot flue gases ...

Page 37: ...adaptor and flexible pipe See figure from page 11 and 17 For exhaust vent pipe material Do not use any other vent material IMPORTANT Note For SS venting system order transition adaptors from the above mentioned suppliers WARNING The use of vent material other than listed UL ULC stainless steel and PPs positive pressure vent pipe and fittings can cause property damage severe personal injury and or ...

Page 38: ... Code or CAN CSA B149 2 Propane Installation Code as applicable in the U S use the National Fuel Gas Code ANSI Z223 1 or NFPA Standard 54 To ensure safe operation of the appliance Viessmann recommends that the system be inspected once a year by a qualified service technician Every venting system must be planned and installed for optimum performance and safety These Installation Instructions are de...

Page 39: ... exhaust vents as described in this section Ensure the vent and combustion air supply comply with these instructions See also page 34 The boiler location should never be under negative pressure Exhaust fans attic fans or dryer fans may cause air to be exhausted at a rate higher than the air can enter the structure for safe combustion Corrective action must be taken to ensure enough air is availabl...

Page 40: ...opylene supplied by the vent manufacturer Side wall vent termination stainless steel CPVC or PP Side wall Support bracket Termination elbow with screen Vent Caulk Max 36 in 915 mm Min 12 in 305 mm Field fabricated vent riser Grade or max snow level Min 26 in 660 mm Stainless steel or plastic mesh Intake terminal 90o Min 12 in 305 mm Exhaust vent terminal 45o Grade or max snow level WARNING Vent te...

Page 41: ...ide must be UV resistant polypropylene supplied by the vent manufacturer Side wall vent termination stainless steel or PP Min 12 in 305 mm Exhaust vent terminal 90o Grade or max snow level Side wall Support bracket Termination elbow with screen Vent Caulk Max 36 in 915 mm Min 12 in 305 mm Field fabricated vent riser Grade or max snow level Flue Min 2 in Max 36 in 50 mm 915 mm ...

Page 42: ...NT A vent used in a special venting system with positive vent pressure and passing through a roof shall extend at least 18 in 450 mm above the highest point where it passes through the roof and any other obstruction within a horizontal distance of 18 in 450 mm The special vent system shall not be routed into through or within any other vent such as an existing masonry or factory built chimney A ma...

Page 43: ... and spacing vary The following types of braces are available at your local vent material supplier wall band wall band extension guy wire band roof brace Ensure that the venting system is properly supported the boiler is not designed to support the weight of the venting system Vent system suppliers To order approved PP s vent system contact the following suppliers M G Duravent Tel 800 835 4429 Tel...

Page 44: ...ssal 200 CM2 400 500 and 620 Installation Two Pipe System Vertical Exhaust Vertical Air Intake Flue Air a Equivalent length exhaust b Equivalent length air intake Note See table on page 47 Venting Options Stainless Steel PP ...

Page 45: ...ws must be secured in place as specified by manufacturer IMPORTANT For PP s systems all exhaust vent and air intake piping and elbows exposed outside must be UV resistant polypropylene supplied by the vent manufacturer IMPORTANT Dimensions a min 18 in max 48 in b min 4 in c min 12 in d 6 in over max local snow level check with your local weather office for details Vertical Vent Installation Flat R...

Page 46: ...M2 400 500 and 620 Installation Two Pipe System Horizontal Exhaust Horizontal Air Intake a Equivalent length exhaust b Equivalent length air intake Flue Air Min 24 in 610 mm Note See table on page 47 Venting Options Stainless Steel PP ...

Page 47: ... 250 8 200 10 250 10 250 12 300 8 200 12 300 12 300 Max equivalent length a b ft m 200 60 Contact Viessmann for vent length calculation Maximum allowable equivalent length Stainless steel PP Two Pipe System Vertical Horizontal Installations Note If flexible vent or air intake pipe are used the total max equivalent length will be reduced by 25 150 ft 45 m a Equivalent length exhaust b Equivalent le...

Page 48: ...tal Exhaust Room Air Dependant Single Pipe System Vertical Exhaust Room Air Dependant a Equivalent length exhaust Flue Air Combustion Air Opening Note See table on page 49 a Equivalent length exhaust Flue Air Combustion Air Opening Note See table on page 49 Venting Options Stainless Steel PP ...

Page 49: ... 620 Flue gas in mm combustion air in mm 10 250 8 200 10 250 10 250 12 305 12 305 Max equivalent length a b ft m 200 60 Contact Viessmann for vent length calculation Note If flexible vent or air intake pipe are used the total max equivalent length will be reduced by 25 150 ft 45 m Horizontal vent termination Vertical vent termination 4 in min 100 mm min 6 in min 150 mm min 36 in min 915 mm min Not...

Page 50: ...5773 597 04 Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Vitocrossal 200 CM2 400 500 and 620 Installation ...

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