Viessmann VITOCROSSAL 200 Gebrauchsanweisung

Technical Data Manual

5773 596 v1.0 06/2013

VITOCROSSAL 200

Gas-fired Condensing Boiler

1445 to 2245 MBH (423 to 658 kW)

Please file in Service Binder

Model Nos. and pricing : See Price List

Vitocrossal 200

CM2 Series 400, 500 and 620

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: 1445 to 2245 MBH

(423 to 658 kW)

Product may not be exactly as illustrated.

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 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 counter flow.

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 pre-wired 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

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Vitocrossal 200

Product Information

Legend

ASupply/return temperature of 176/140° F (80/60° C)

BSupply/return temperature of 158/122° F (70/50° C)

CSupply/return temperature of 140/104° F (60/40° C)

DSupply/return temperature of 122/86° F (50/30° C)

ESupply/return temperature of 104/68° F (40/20° C)

Flue gas temperature as a function of average partial load firings.

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Product Information

Cutaway Section

Legend

AStainless steel Inox-Crossal heat exchanger

BHighly effective thermal insulation

CWater-cooled stainless steel combustion chamber

DWide water passageways - good natural circulation

EModulating MatriX cylinder burner

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Technical Data

Specifications

Boiler Model CM2 400 500 620

Input MBH 1445 1800 2245

(kW) (423) (527) (658)

Minimum Input NG MBH 287 358 450

(kW) (84) (105) (132)

Minimum Input LPG MBH 351 440 545

(kW) (103) (129) (160)

Output*1MBH

(kW)

1372

(402)

1710

(501)

2132

(625)

Net AHRI rating MBH

(kW)

1193

(350)

1487

(436)

1854

(543)

Combustion efficiency*1% 95.1 95.1 95.1

Thermal efficiency*1% 95.0 95.0 95.0

Overall length(e) in. 89b955/81007/8

(mm) (2273) (2429) (2562)

Overall width (c) in. 423/8423/8443/8

(including insulation) (mm) (1078) (1078) (1128)

Overall height (a) in. 655/8655/868c

(including control unit)*2(mm) (1666) (1666) (1748)

Concrete boiler base

Length in. 465/853 58

(mm) (1185) (1345) (1475)

Width in. 42.5 42.5 44.5

(mm) (1245) (1245) (1295)

Thickness in. 4 4 4

(mm) (100) (100) (100)

Weight

Boiler body lb 1136 1257 1488

(Kg) (515) (570) (675)

Complete with the burner, control lb 1495 1662 1929

and thermal insulation (Kg) (678) (754) (875)

Note: For high altitude installations 5,000 to 10,000 ft. (1500 to 3000 m), the input will have an altitude de-ration of

15% for 5,000 ft. (1500 m) and 18% for 10,000 ft. (3000 m)

*1Tested to U.S. Standards ANSI Z21.13/CSA 4.9 and AHRI, BTS-2000 Testing Standard Method to determine the

efficiency of Commercial Heating Boilers.

*2Add 1f in. (40 mm) when using seismic mounts (optional accessory).

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Specifications

Technical Data (continued)

Boiler Model CM2 400 500 620

Boiler Water Content USG 104 112 131

(L) (395) (425) (495)

Heat exchanger surface ft.2166.6 208.6 234

water cooled (m2) (15.5) (19.4) (21.7)

Maximum Operating Temperature °F (°C) 210 (99) 210 (99) 210 (99)

Maximum Adjustable High Limit °F (°C) 95 (203) 95 (203) 95 (203)

Maximum Operating Pressure psig 75 75 75

(bar) (5) (5) (5)

Boiler Connections

Boiler supply and return (BS), (BR) in. 4 4 4

(ANSI flanges) (mm) (100) (100) (100)

Safety Supply in. 1a1a1a

Boiler Drain in. 1b1b1b

Condensate Drain in. ¾¾¾

Vent pipe

Internal Diameter in. 10 10 10

(mm) (252) (252) (252)

Flue Gas Values

temperature (at a return

temperature of 86° F (30° C)

at rated input °F 113 113 113

(°C) (45) (45) (45)

at partial load °F 86 86 86

(°C) (30) (30) (30)

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 1276 1587 1986

(kg/h) (579) (720) (901)

at partial load lbs/h 255 317 399

(kg/h) (116) (144) (181)

Pressure

at boiler flue outlet pa 70 70 70

at rated input “w.c. 0.28 0.28 0.28

Standby loss

at maximun input and steady

state condition 180° F/80° F

(82° C/27° C) supply and

return water temperature

At boiler water temperature

158° F (70° C) [room

temperature 68° F (20° C)] BTU/h (W)

1878 (550)

0.13

2520 (738)

0.14

3367 (986)

0.15

At boiler water temperature

158° F (70° C) [room

temperature 68° F (20° C)] BTU/h (W)

4335 (1270)

0.3

5400 (1580)

0.3

6735 (1973)

0.3

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Dimensions

Specifications

Legend

A Boiler Length

B Boiler Width

C Boiler Height

AGA Flue outlet

BO Inspection Opening (Canada only)

E Drain

KOA Condensate drain

KTS Boiler water temperature sensor

KR Boiler return

KV Boiler flow

RG Female connection Rbfor additional control

equipment (e.g. fitting assembly with minimum

and maximum pressure switch)

SA safety connection (safety valve)

STB Flue outlet

Dimensions

Model CM2 400 500 620

a* in. (mm) 655/8(1666) 655/8(1666) 68c(1748)

b* in. (mm) 56a(1428) 56a(1428) 59b(1511)

c in. (mm) 423/8(1078) 423/8(1078) 443/8(1128)

d=B in. (mm) 35c(910) 35c(910) 37c(960)

e in. (mm) 89b(2273) 955/8(2429) 1007/8(2562)

f in. (mm) 85a(2163) 85a(2319) 96c(2455)

g in. (mm) 46c(1187) 527/8(1343) 58a(1477)

h=A in. (mm) 59 (1497) 65 (1650) 703/8(1787)

i in. (mm) 217/8(555) 28c(713) 33b(851)

j=BO in. (mm) 4 (101) 4 (101) 4 (101)

k in. (mm) 34a(870) 34a(870) 345/8(879)

l in. (mm) 15d(383) 12c(435) 187/8(480)

m in. (mm) 10 (254) 12d(308) 13c(351)

n in. (mm) 12b(318) 145/8(370) 163/8(415)

o in. (mm) 2c(70) 2c(70) 25/8(67)

p* in. (mm) 277/8(708) 277/8(708) 29 (736)

q* in. (mm) 53b(1360) 545/8(1387) 57b(1460)

r=C* in. (mm) 583/8(1482) 593/8(1509) 62a(1582)

s in. (mm) 23c(601) 23c(601) 23c(601)

t* in. (mm) 9 (229) 9 (229) 9 (229)

u* in. (mm) 57/8(149) 57/8(149) 57/8(149)

v in. (mm) 5a(133) 5a(133) 5a(133)

* Add 1f in. (40 mm) when using seismic mounts (optional accessory).

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

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 400 500 620

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 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)

Specifications

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data Specifications

Flow Rate

Pressure drop (primary circuit)

The Vitocrossal 200 is only suitable for fully pumped hot

water heating systems.

Recommended Flow Rates CM2

Boiler model 400 500 620

20° F rtGPM 137.2 171.0 213.2

40° F rtGPM 68.6 85.5 106.6

11° C rtm3/h 31.1 38.8 48.4

22° C rtm3/h 15.5 19.4 24.2

rt = temperature difference

This boiler does not require a flow switch.

Pressure drop

Flow rate

5773 596 v1.0

Vitocrossal 200, CM2-400, -500 and -620 Technical Data

Cylinder Burner

Specifications

Boiler Model CM2 400 500 620

Voltage V 120 120 120

Frequency Hz 60 60 60

Power consumption NG

at max. input W 540 700 900

at min. input W 54 60 60

Power consumption LPG

at max. input W 467 590 700

at min. input W 59 68 60

Version modulating

Dimensions

Length in. (mm) 385/8(980) 385/8(980) 41¾(1060)

Width in. (mm) 26 (661) 265/8(675) 265/8(675)

Height in. (mm) 21a(540) 205/8(525) 24b(622)

Weight

Burner only

Burner package (with kits, flanges and

mounting hardware)

lb. (kg)

75 (34)

91 (41.3)

90 (41)

93 (42)

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 1a1a1a

Specifications

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