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Viessmann VITOCROSSAL 200 CI2 Series User Manual

Viessmann VITOCROSSAL 200 CI2 Series
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Installation Instructions
VITOCROSSAL 200
6175 796 - 07 10/2022
for use by heating contractor
Vitocrossal 200 CI2 series
Gas condensing boilers with MatriX cylinder burners
Heating input: 399 to 2000 MBH
(117 to 586 kW)
Read and save these instructions
for future reference.
Please file in Service Binder
Product may not be exactly as shown
IMPORTANT
H

Table of Contents

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Viessmann VITOCROSSAL 200 CI2 Series Specifications

General IconGeneral
TypeCondensing Gas Boiler
ModelVITOCROSSAL 200 CI2 Series
Efficiencyup to 98%
Heat ExchangerStainless Steel
Max Flow Temperature85°C
Fuel TypeNatural Gas / Propane
Control SystemVitotronic Control
Connection (Heating Flow/Return)1 1/4"
Noise Level50 dB(A)

Summary

Safety, Installation and Warranty Requirements

Product documentation

Read all applicable documentation before installation. Store near boiler for service personnel.

Warranty

Information in documentation must be read and followed; failure voids warranty.

Licensed professional heating contractor

Installation, adjustment, service by licensed professional.

Carbon monoxide

Improper installation can cause flue products to flow into living space.

Fresh air

Equipment requires fresh air for safe operation.

Contaminated air

Air contaminated by chemicals can cause by-products.

Equipment venting

Never operate without venting system; improper system causes poisoning.

Advice to owner

Familiarize owner with equipment, safety, shutdown, and annual service.

Fiberglass wool and ceramic fiber materials

Handling precautions and first aid for fiberglass/ceramic fibers.

Codes

Installation must comply with local, national codes (NFPA, CSA, ANSI).

Mechanical room

Requirements for mechanical room, including temperature limits.

General Information

Important Regulatory and Installation Requirements

Massachusetts modifications to NFPA-54 chapter 10, CO detectors, signage.

About these Installation Instructions

Explanation of warning, caution, and important symbols used in the manual.

Intended Use

Boiler is for sealed unvented heating systems and heating water only.

Mechanical Room

Boiler location requirements, combustion air quality.

For Retrofit Applications

Requirements for flushing heating system piping before connecting boiler.

Preinstallation

Recommended Minimum Service Clearances

Dimensions for installation and maintenance clearances around the boiler.

Mechanical room

Avoid air contamination, dust, humidity; ensure ventilation.

Unpacking the Boiler

Step-by-step instructions for unpacking the boiler from its pallet.

Placement of Boiler

Boiler placement on a load-bearing foundation and leveling.

WiFi Operational Reliability and System Requirements

Requirements for WiFi router, internet connection, and signal range for boiler.

LAN Connection

Information on connecting the appliance via the LAN socket.

Installation

Boiler Connections

Diagram and specifications for boiler supply, return, and other connections.

Boiler Connections (continued)

Boiler suitability for hot water, safety header details.

Boiler Connections (continued)

Detailed diagram of safety header and connections.

Gas Connections

Diagrams and legends for gas connections for different models.

Gas Connections (continued)

Connecting gas pipe, leak testing, purge, and fuel supply recommendations.

Gas Connections (continued)

Referencing codes, piping layout, pressure test, valve leak test.

Electrical Connections

Instructions for removing front panels to access control units.

Electrical Connections (continued)

Opening control unit cover and routing cables.

Electrical Connections (continued)

Location of control unit components for different models.

Electrical Connections (continued)

Overview of connections to the wiring panel and MZIO.

Electrical Connections (continued)

Connecting ventilation air supply, external blocking, 0-10V connections, sensor.

Electrical Connections (continued)

Outside temperature sensor, tank temperature sensor, assigning functions.

Connecting the circulation pumps

Connecting circulation pumps to P1, P2, ZP1, ZP2, ZP3.

Electrical Connections (continued)

Pump connection diagrams for various voltage supplies.

Electrical Connections (continued)

Checking CAN bus terminator switch setting, connecting cascade.

Electrical Connections (continued)

Accessories with direct power supply, connecting PlusBus subscribers.

Electrical Connections (continued)

Subscriber numbers of connected extensions and rotary switch settings.

Electrical Connections (continued)

Overview of DIN rail terminal block connections.

Electrical Connections (continued)

Accessory connections and DIN rail fuses F1 replacement.

Electrical Connections (continued)

Isolation valve and pump connection details.

Electrical Connections (continued)

Pump connection diagrams for different voltage supplies.

Electrical Connections (continued)

Connection of Low Water Cut-off Device.

Boiler Power Supply

Wiring diagrams and code compliance for boiler power supply.

Venting

Connections on the Flue Gas Side

Fitting the condensate trap on the flue gas side.

Condensate Connection

Requirements for condensate drain pipe, connections, and neutralization.

Connections on the Flue Gas Side

Connecting the neutralizing system (accessories) for condensate.

Installation

Initial System Fill General Requirements

Requirements for boiler feed water, antifreeze, system flushing, and pressure.

System Layout

General

General notes on system layout schematics and installation responsibility.

System Layout 1

Diagram of a system with DHW tank, 3 zone circuits, and 3 mixing valve circuits.

System Layout 2

Diagram of a system with DHW tank, 3 zone circuits, and 3 mixing valve circuits.

System Layout 3

Diagram for multiple boilers with heating/zone circuits and DHW.

System Layout 4

Diagram for multiple boilers with system pump and DHW.

Boiler Piping in Heating/Cooling Application

Boiler piping for heating/cooling applications with refrigeration systems.

Venting

Connections on the Flue Gas Side

Connecting the flue outlet and flue pipe, and accessories.

Connections on the Flue Gas Side (continued)

Connecting flue gas collector, vent system installation, and pipe sizes.

General Venting Information

Installation steps, safety warnings, and recommended venting practices.

General Venting Information (continued)

Combustion air intake materials and pipe requirements.

General Venting Information (continued)

Vent termination location requirements for Canada and USA.

General Venting Information (continued)

Flashing and storm collar installation, combustion air intake.

Additional Requirements for Stainless Steel Vent Pipe Material

Suppliers and requirements for stainless steel vent pipe.

Requirement for Rigid SS/PP(s)/CPVC Vent Pipe Material

Requirements for PP(s) and stainless steel vent pipe, suppliers.

Adaptor Chart

Chart for vent material adaptors for different boiler models.

Vent Requirements

Combustion air supply requirements and boiler location.

Direct Venting (Two Pipe System)

Side wall vent termination requirements and diagrams.

Side Wall Venting

Side wall vent termination requirements and component installation guide.

Elbow - Equivalent Length

Table showing equivalent lengths for 45° and 90° elbows.

Vent Termination Location Requirements - Vertical

Vertical vent termination requirements and installation of support systems.

Venting Options - Stainless Steel/PP(s)/CPVC

Two Pipe System - Vertical Exhaust/Vertical Air Intake

Diagram and specifications for vertical venting systems.

Two Pipe System - Vertical Exhaust/Vertical Air Intake

Diagrams for vertical vent installation on sloped and flat roofs.

Two Pipe System - Horizontal Exhaust/Horizontal Air Intake

Diagram and specifications for horizontal venting systems.

Two Pipe System - Vertical Exhaust/Horizontal Air Intake

Diagram and specifications for mixed vertical/horizontal venting.

Single Pipe System - Vertical Exhaust/Room Air Dependant

Diagram and specifications for vertical single-pipe venting.

Single Pipe System - Horizontal Exhaust/Room Air Dependant

Diagram and specifications for horizontal single-pipe venting.

Multiple Boiler Installations

Minimum distance requirements for horizontal and vertical vent terminations.

Additional Information

Lighting and Operating Instructions

Safety instructions before operating and step-by-step operating procedures.