Viessmann Vitocrossal 200 CM2 400

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Operating Instructions

VITOCROSSAL 200

5546 488 - 02 01/2023

for use by heating contractor

Vitocrossal 200

CM2 Series 186, 246, 311, 400, 500, 620 and 620 TX

Gas condensing boiler with cylinder burner

Read and save these instructions for

future reference.

Please file in Service Binder

Heating input: 663 to 2245 MBH

194 to 658 kW

Product may not be exactly as illustrated.

Do not store or use gasoline or other

ammable liquids in the vicinity of this

or any other appliance.

WHAT TO DO IF YOU SMELL GAS

g Do not try to light any appliances.

g Do not touch any electrical switches,

do not use any phone in your building.

g Immediately call your gas supplier

from a neighbor’s phone. Follow

the gas supplier’s instructions.

g If you cannot reach your gas supplier,

call the re department.

Installation and service must be

performed by a qualied installer,

service agency or the gas supplier.

WARNING

If the information in this manual is not followed

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

WARNING

Improper installation, adjustment, and/

or operation could cause carbon monoxide

poisoning resulting in injury or loss of life.

This product must be installed and serviced

by a professional service technician who is

experienced and qualified in hot water boiler

installation and gas/oil combustion.

IMPORTANT

Other manuals for Viessmann Vitocrossal 200 CM2 400

Service Instructions76 pages

Installation Instructions36 pages

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Overview

Function Description
Usage Features
Maintenance Features
Monthly Maintenance (Owner/Operator)
Annual Maintenance (Owner/Operator & Heating Contractor)
Periodic Maintenance (Heating Contractor)
Additional Maintenance Information

The Vitocrossal 200, CM2 Series, is a gas condensing boiler designed for heating applications, suitable for both residential and commercial use. This boiler operates without a low-temperature limit, allowing for efficient performance across a range of operating conditions. It is controlled by a Vitotronic control system, which integrates indoor and outdoor temperature sensors to optimize boiler operation and energy consumption. The control system must be programmed by a qualified installer to ensure proper functionality and adherence to the specific heating requirements of the installation.

Function Description

The primary function of the Vitocrossal 200 is to provide hot water for heating systems. As a condensing boiler, it extracts additional heat from the flue gases by condensing the water vapor present in them. This process significantly increases efficiency compared to conventional boilers, leading to lower fuel consumption and reduced emissions. The boiler is designed for closed-loop hot water heating systems and requires a pre-charged membrane expansion tank for proper operation.

The Vitocrossal 200 can also be used for domestic hot water production when connected to an indirect-fired hot water storage tank. The Vitotronic control system includes the necessary control circuits for managing domestic hot water production, ensuring that hot water is available as needed. Proper connections to the boiler and the use of a correctly sized circulating pump are essential for this function.

The boiler's operation is monitored by its controls, which work in conjunction with any installed system controls, such as indoor/outdoor controls and setback programming. These controls allow for precise management of the heating system based on various settings, ensuring comfort and energy efficiency.

Usage Features

To operate the Vitocrossal 200 safely and efficiently, users should be familiar with its basic functions and safety precautions. The boiler features an ON indicator (green) to show when it is operational and a Fault indicator (red) to signal any issues. An ON/OFF switch allows for manual control of the boiler's power.

Before starting the heating system, it is crucial to check the system pressure at the pressure gauge. If the pressure is too low, the system water needs to be topped up. The gas shut-off valve must be open, and the main power supply to the boiler and any additional controls must be switched ON. Once these steps are completed and the ON/OFF switch is activated, the boiler's standard menu will be displayed, and the green ON indicator will illuminate, indicating that the heating system is ready for use.

For systems with additional controls, such as aquastats or mixing valves, users should refer to their respective operating instructions to understand how these components interact with the boiler.

In case of system shutdown, the main power switch and all additional switches controlling pumps or controls, including the main switch for the burner, should be deactivated. All valves in the system should also be closed. It is important to consult the operating instructions for the Vitotronic control and the gas burner before activating or deactivating the heating system.

Maintenance Features

Regular inspection and service are critical for the Vitocrossal 200's performance, efficiency, and longevity. A qualified heating contractor should perform annual service and maintenance. Neglecting maintenance can impact the warranty and lead to inefficient operation.

Monthly Maintenance (Owner/Operator):

System Pressure: Frequently check the system pressure.
Boiler Control: Ensure proper operation of the boiler control.
Seals: Inspect all seals; retighten or replace as necessary.
Combustion/Ventilation Air: Ensure an adequate supply of combustion and ventilation air into and out of the mechanical room. Nothing should obstruct the flow of this air.
Storage: Ensure no chemicals, garbage, gasoline, combustible materials, flammable vapors, or liquids are stored near the boiler.
Leaks: Check for water on the floor from the discharge pipe of the pressure relief valve or any other pipe, joint, valve, or air vent.
Pressure Relief Valve: Test the pressure relief valve and check for proper operation.
High Limits: Check all operational high limits for proper operation.
Condensate Neutralization System (if used): Check for proper operation, condition, and fill status of the neutralization media.
Flue Gas Condensate: Check the pH value of the flue gas condensate.
Vent Pipe/Chimney: Check for moisture/water on vent pipe joints and the appearance of ice on the vent pipe or chimney outlet in winter.

Annual Maintenance (Owner/Operator & Heating Contractor):

Service Work: Ensure service work/tests are conducted at least annually by a qualified heating contractor, and any deficiencies are corrected immediately.
Safety High Limits: Test functionality of safety high limits.
Burner: Test the burner with burner accessories according to the corresponding maintenance checklist.
System Water: Test and establish proper chemical makeup of system water.
Flue Pipe/Chimney: Check flue pipe condition, chimney connection, and the chimney itself.
Pressure Relief Valve/System Pressure: Check and verify proper operation.
Heating Pipe Joints/Valves/Air Vents: Check for leaks; correct immediately to avoid further defects and determine the cause.
Combustion Air Supply/Ventilation: Check for proper supply and ventilation of the boiler/mechanical room.
Combustible Materials/Chemicals: Check for materials or chemicals stored too close to the boiler.
High Limits/Low Water Cut-off: Test high limits by dialing lower settings, switching the burner on/off. If a low water cut-off is installed, check and verify its proper function according to the manufacturer's instructions.

Periodic Maintenance (Heating Contractor):

Circulating Pump: If field-installed, check maintenance/lubrication requirements per manufacturer's specifications.
Gas Connections: Check for gas-tight connections of gas piping, unions, gas valve, and manifold.
Ignition/Burner Operation: Check proper ignition and gas burner operation.
Combustion Test: Must be performed by a qualified heating contractor.
Low Water Cut-offs: Ensure functionality during operation based on supplier's instructions.
Gas Switch: Inspect low- and/or high-pressure gas switch (if used).
Main Burner Flame: Inspect and follow burner manufacturer's instruction manual for detailed service and maintenance.
Boiler Room Cleanliness: Keep boilers and boiler room free of high dust levels, high humidity, aggressive vapor, and/or chemicals containing chlorine.
Boiler Room Ventilation: Ensure proper ventilation.
Valves/Fittings/Pipes: Check and repair.
Combustion Chamber Door/Flanges: May need to be retightened and resealed.

Additional Maintenance Information:

Danger of Freezing: If the system is subject to freezing temperatures and is not filled with antifreeze, the system (including the boiler) must be drained. Valves before the automatic feed valve (if installed) must be closed, and all other valves, air vents, and drain valves must remain open.
Long Periods of Shut-down: After the heating season, the combustion chamber, flue gas collector, and vent pipe should be cleaned to avoid corrosion. The heating system can remain filled and under pressure. Remaining condensate should be removed from the flue gas collector via the front inspection service opening.
Water Quality: Water quality significantly influences the heating system's lifetime. A water treatment system can protect against corrosion and lime formation. Hard water conditions should be avoided as they can cause deposits on heat exchanger surfaces. If in doubt, a proper water analysis should be performed, and regional chemical suppliers or Viessmann Manufacturing Company Inc. should be consulted for boiler water treatment.

The boiler room must be safe from frost and properly ventilated. The boiler should not be located in areas with halogenated hydrocarbons or aggressive vapors, as these can cause heat exchanger corrosion and reduce the boiler's lifetime. Carbon monoxide detectors are strongly recommended in buildings with gas-burning equipment. The installer is required to confirm that at least one carbon monoxide alarm is installed in the living space before the appliance is put into operation.

Viessmann Vitocrossal 200 CM2 400 Specifications

General

Type	Gas condensing boiler
Model	Vitocrossal 200 CM2 400
Max. nominal heat output	400 kW
Efficiency	Up to 98% (Hs) / 109% (Hi)
Heat exchanger material	Stainless steel
Modulation range	1:5
Operating pressure	Up to 6 bar
Fuel type	Natural gas, LPG
Heat exchanger	Inox-Crossal
Control system	Vitotronic