VIESMANN VITOCROSSAL 200Gas condensing boiler

404 to 628 kW

VITOCROSSAL 200 Type CT2

Gas condensing boiler for natural gas E and LLWith modulating MatriX cylinder burner

5822 448 GB 6/2009

DatasheetPart numbers and prices: see pricelist

■ Condensing Unit with MatriX cylinder burner as two-boiler systemup to 1256 kW.

■ Seasonal efficiency [to DIN]: up to 98% (Hs)/109% (Hi).■ The stainless steel, corrosion-resistant Inox-Crossal heating surface

ensures high operational reliability and a long service life.■ Inox-Crossal heating surface for highly effective heat transfer and

high condensation rate.

■ Self-cleaning effect through smooth stainless steel surface.■ MatriX cylinder burner for particularly quiet and environmentally

responsible operation with a modulating range of 33 to 100%.■ Optional open flue or balanced flue operation.■ Cascade with pre-assembled accessories on the hydraulic and flue

gas side.

A Inox-Crossal heating surfaces made from stainless steelB Highly effective thermal insulationC Water cooled stainless steel combustion chamberD Wide water galleries – good natural circulationE Modulating MatriX cylinder burner

Benefits at a glance

2 VIESMANN VITOCROSSAL 200

5822

448

GB

Specification

Rated output TV/TR = 50/30 °C kW 135-404 168-503 209-628TV/TR = 80/60 °C kW 123-370 153-460 192-575Rated thermal load kW 127-381 158-474 198-593Product ID CE-0085 BS 0399Permiss. operating temperature °C 95 95 95Permissible flow temperature(= safety temperature)

°C 110 110 110

Permiss. operating pressure bar 5.5 5.5 5.5Boiler body dimensions Length (dimension a) mm 1315 1494 1550Width excl. boiler door mm 805 805 805Width incl. boiler door mm 845 845 845Height (incl. connectors) mm 1930 1930 1930Overall dimensions Total length incl. burner hood (dimension b) mm 1820 1900 2055Total width incl. control unit mm 1200 1200 1200Total height mm 1985 1985 1985Foundations Length mm 1250 1300 1500Width mm 900 900 900Height mm 100 100 100Weight – Boiler body kg 596 639 768Total weight – Boiler with burner, thermal insulation and boiler control unit kg 736 790 928Content boiler water litres 260 324 405Boiler connections Boiler flow PN 6 DN 100 100 100Boiler return PN 6 DN 100 100 100Safety connection (safety valve) PN 16 DN 50 50 50Drain R 1 1 1Condensate drain, flue gas collector/siphon 7mm 32/20 32/20 32/20Flue gas parameters*1

Temperature (at 30 °C return temperature)

– at rated output °C 45 45 45– at partial load °C 40 40 40Temperature (at 60 °C return temperature) °C 75 75 75Mass flow rate (for natural gas) – at rated output kg/h 578 719 900– at partial load kg/h 193 240 300Available draught Pa 70 70 70to the flue outlet*2 mbar 0.7 0.7 0.7Flue gas connection 7 mm 250 250 250Seasonal efficiency [to DIN] at heating system temp. 40/30 °C % up to 98 (Hs)/109 (Hi)at heating system temp. 75/60 °C % up to 95 (Hs)/106 (Hi)Standby loss qb,70 % 0.25 0.24 0.23

*1 Calculating values for sizing the flue system to EN 13384, based on 10 % CO2 for natural gas.Flue gas temperatures measured as gross values at 20 °C combustion air temperature.The details for partial load refer to 33% of rated output. Calculate the flue gas mass flow rate accordingly when the partial load differs fromthat stated above (subject to burner mode).

*2 When using the Vitocrossal 200 with moisture-resistant stacks, the draught may be max. 0 Pa.

Boiler specification

VITOCROSSAL 200 VIESMANN 3

5822

448

GB

1050

1985

795

ab

SA

247

RG

KV

SA

KTS

DB

241

504

577

1190

1827 1932

KR

DB

KRE

AGARLU

KOA

1200

KV

AGA Flue outletDB G ½" fem. connection for pressure limiter E DrainKOA Condensate drainKR Boiler returnKTS Boiler water temperature sensor

KV Boiler flowRG Fem. connection G ½" for additional control equipmentRLU Ventilation air connection 7 200/250 mm for balanced flue

operation (accessory)SA Safety connection (safety valve)

DimensionsRated output kW 404 503 628a mm 1315 1390 1550b mm 1820 1900 2055

Installation

Minimum clearances

1000500

500a

500

(50)

AE

D CB

b

A BoilerB Burner with burner hoodC Hydraulic system connection (accessory)D Flue gas header (accessory)E Anti-vibration boiler supports (accessory)

To enable convenient installation and maintenance, observe the sta-ted clearance dimensions; maintain the minimum clearances wherespace is tight (dimensions in brackets). In the delivered condition, theboiler door opens to the left. You can reposition the hinge brackets sothat the door can open to the r.h. side.

Recommended clear-ance excl. accessories

In case of flue gas header(accessory) for two-boiler sys-tems

Dimen-sion a

700 mm 1000 mm

Dimen-sion b

— 1550 mm

Boiler specification (cont.)

4 VIESMANN VITOCROSSAL 200

5822

448

GB

Installation■ Avoid air contamination through halogenated hydrocarbons (e.g. as

in sprays, paints, solvents and cleaning agents)■ Avoid very dusty conditions■ Avoid high levels of humidity■ Prevent freezing and ensure good ventilation

Otherwise, the system may suffer faults and damage.In rooms where air contamination from halogenated hydrocarbonsis to be expected, operate the boiler only in balanced flue mode.

Pressure drop (primary circuit)

60

8070

87

1

2

3456

10

20

30

405060

100

2 3 4 5 6 7 8 10 20 30 40 50

Pres

sure

dro

p in

mba

r

Flow rate in m³/h

The Vitocrossal 200 is only suitable for fully pumped hot water heatingsystems.

Boiler specification (cont.)

VITOCROSSAL 200 VIESMANN 5

5822

448

GB

Specification

Rated boiler outputTV/TR 50/30 °C

kW 404 503 628

Burner output, lower/upper*3 kW 127/381 158/474 198/593Burner type VM IV-1 VM IV-2 VM IV-3Product ID CE-0085 BS 0400Voltage V 230Frequency Hz 50Power consumption at upper output W 575 620 880at lower output W 80 85 95Version modulatingDimensions Length (dimension b) mm 632 632 632Total length (dimension c) mm 927 967 1027Length incl. burner hood (dimension a) mm 653 653 653Width (dimension d) mm 844 844 844Height (dimension e) mm 935 935 935WeightBurner with combination valve and burner hood

kg 41 48 50

Gas supply pressure mbar 20 20 20Gas connection R 1¼ 1¼ 1½Connection values relative to the max. load with – natural gas E m3/h 13.4-40.3 16.7-50.2 21.0-62.8– natural gas LL m3/h 15.6-46.9 19.4-58.3 24.4-73.0

e

A

B

C

D

E

F G

KL M

N

O

d a

c

b

S

R

P

H

A Boiler doorB Air pressure switchC FanD Display and programming unitE Gas supply pipeF Mains filterG Gas trainH Venturi mixing tube

K Burner gauze assemblyL Ignition electrodesM Ionisation electrodeN Thermal insulation blockO Electronic ignitionP Burner hoodR Burner control unitS Rotary damper with servomotor

*3 Corresponds to the rated thermal load of the boiler.

Specification, MatriX cylinder burner

6 VIESMANN VITOCROSSAL 200

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GB

Boiler body with fitted mating flanges and gaskets to all connectorsand fitted protective crate, plus flue gas collector.

1 Carton with thermal insulation1 Carton with MatriX cylinder burner1 Carton with burner hood1 Carton containing the boiler control unit and 1 bag with technical documentation1 Product pack (boiler coding card and technical documentation)

Control unit versions

For single boiler systems:■ without Vitocontrol control panel

Vitotronic 100 (type GC1)for operation with a constant boiler water temperature or for weather-compensated operation in conjunction with a control panel (seebelow) or an external control unit.Vitotronic 200 (type GW1)for modulating boiler water temperaturewithout mixer controlVitotronic 300 (type GW2)for modulating boiler water temperaturewith mixer control for up to two heating circuits with mixer

■ with Vitocontrol control panelVitotronic 100 (type GC1) and LON module (accessories)andVitocontrol control panel with Vitotronic 300-K (type MW1S) forweather-compensated operation and mixer control for up to 2 heat-ing circuits with mixer and additional Vitotronic 200-H, type HK1S orHK3S for 1 or up to 3 heating circuits with mixerorControl panel with external control unit (on site)

For multi-boiler systems:(up to 4 boilers)

■ without Vitocontrol control panelVitotronic 100 (type GC1) and LON module in conjunction witha Vitotronic 300-K (type MW1)for modulating boiler water temperature (one boiler is supplied withthe standard control equipment for a multi-boiler system)andVitotronic 100 (type GC1) and LON module for modulating boilerwater temperaturefor each additional boiler in a multi-boiler system

■ with Vitocontrol control panelVitotronic 100 (type GC1) and LON modulefor modulating boiler water temperaturefor each boiler in a multi-boiler systemandVitocontrol control panel with Vitotronic 300-K (type MW1S) formulti-boiler system, weather-compensated operation and mixer con-trol for up to 2 heating circuits with mixer and additional Vitotronic200-H, type HK1S or HK3S for 1 or up to 3 heating circuits with mixerorControl panel with external control unit (on site)

Boiler accessories

Stainless steel flue gas header for two-boiler system

Connection to the flue system, optional outlet on the l.h. or r.h. side.

Delivered condition

VITOCROSSAL 200 VIESMANN 7

5822

448

GB

Example: (outlet on the r.h. side)

d

3°

b

≤ 12

50

250500430

180

250

≤ 42

0Ø 2

50

Ø a

500

430

250

A Boiler flue connection with test ports and inspection apertureB Motorised flue gas damperC Sliding element, 250 mmD Tee connectorE Sliding element, 500 mm

F Longitudinal part, 500 mmG Inspection coverH Flue pipe with condensate drainK Flue gas system

DimensionsInternaldiameter

mm 300 350 400

a 7mm 300 350 400b mm 1550bmax mm 1680d mm 703

Selection table for the max. draught 70 PaRated output (kW) Diameter of the effective vertical flue pipe up

to 30 metres (in mm)2x370 7 3002x460 7 3502x575 7 400

Use a flue pipe with the same diameter as that of the flue gasheader.Secure the boiler flue connection with a floor connector and keep freeof load or torque stresses.

NoteDetails refer to open flue operation.

Boiler accessories (cont.)

8 VIESMANN VITOCROSSAL 200

5822

448

GB

Hydraulic system pipework for two-boiler system

B

A

C

D

DB

a

150

A Flow manifoldB Mating flanges with gasketsC Return collectorD Motorised butterfly valves

Dim. a: 1550 mm

Rated output in kW Int. dia.Single boiler Dual-boiler system 404503628

80810061256

DN 100/125

Additional accessoriesSee pricelist and "Boiler accessories" datasheet.

Operating conditions

For water quality requirements, see the technical guide to this boiler.

Requirements1. Heating water flow rate None2. Boiler return temperature (minimum value) None3. Lower boiler water temperature None4. Reduced mode None – total reduction is possible5. Weekend setback None – total reduction is possible

Design information

Installation for balanced flue operationAs equipment type C33, C43, C53, C63 or C83 to TRGI 2008, theVitocrossal can be operated in balanced flue mode.

Installation for open flue operation(B23, B23P, B33)

Boiler accessories (cont.)

VITOCROSSAL 200 VIESMANN 9

5822

448

GB

For open flue combustion equipment with a total rated output in excessof 50 kW, the fresh ventilation is deemed to have been verified if thecombustion equipment is located in areas which provide an apertureor duct leading outdoors.The cross-section of the aperture must be at least 150 cm2 and mustbe 2 cm2 larger for each additional kW above 50 kW rated output.

Pipes must be sized to provide equivalent flow rates. The requiredcross-section may be split over a maximum of two apertures orpipes.

NeutralisationDuring condensation an acidic condensate with a pH value of between3 and 4 is produced. This condensate can be neutralised by process-ing it through a neutralising system.

For further information, see the technical guide and "Boiler accesso-ries" datasheet.

Burner adjustmentMatriX cylinder burner tested at operating temperature and adjustedin the factory.

Further information on design/engineeringSee the technical guide to this boiler

Approved quality

CE designation according to current EC Directives.

Design information (cont.)

10 VIESMANN VITOCROSSAL 200

5822

448

GB

Prin

ted

on e

nviro

nmen

tally

frie

ndly

,ch

lorin

e-fre

e bl

each

ed p

aper

Subject to technical modifications.

Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: info-uk@viessmann.com

Viessmann Werke GmbH&Co KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com