Viessmann VITOCROSSAL 200 User Manual

Viessmann VITOCROSSAL 200

72 pages

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Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CM2

Gas condensing boiler

For applicability, see the last page

VITOCROSSAL 200

5692 681 GB 4/2009

Please keep safe.

Table of Contents

Other manuals for Viessmann VITOCROSSAL 200

Installation Instructions64 pages

Technical Data Manual16 pages

Service Instructions96 pages

Operating Instructions12 pages

Installation Instructions For Contractors32 pages

Service Instructions For Contractors88 pages

Questions and Answers:

J
James WilliamsSep 5, 2025
What to do if Viessmann Boiler burner control unit is in fault state?
- H
  Heather JamesSep 5, 2025
  If the burner control unit in your Viessmann Boiler is in a fault state, here are some potential causes and solutions: * If valve 1 or valve 2 is leaking, replace the gas train. * If there is an internal fault and the fan cannot reach its set value, replace the burner control unit or fan. * If the safety chain has been opened, check the safety chain. * If there is an internal error in feedback from gas safety valves or the output relay does not respond, replace the burner control unit. * If the safety chain is 'live', check the safety chain. * If it is an EMC fault, have your system tested for EMC interference.
D
Daniel WellsAug 25, 2025
What to do if my Viessmann VITOCROSSAL 200 shows F b7 error?
- J
  Jennifer SimmonsAug 25, 2025
  If your Viessmann Boiler displays error code F b7, it might be due to a missing, incorrect, or faulty coding card in the burner control unit. First, ensure the coding card is properly inserted. If it is, check the card for any damage or inconsistencies. If problems persist, consider replacing the coding card.
P
patriciaavilaAug 25, 2025
Why does my Viessmann VITOCROSSAL 200 Boiler display F b7 error if the coding card doesn't match the burner control unit?
- J
  Joseph SteeleAug 26, 2025
  If your Viessmann Boiler displays error code F b7, it may be because the coding card does not match the burner control unit. Replace the coding card or burner control unit. Important: Ensure the power is off before replacing the coding card.
S
Sean GallegosAug 27, 2025
What does error code F 80 mean on my Viessmann VITOCROSSAL 200 Boiler?
- M
  Melanie VasquezAug 27, 2025
  If your Viessmann Boiler shows the error code F 80, it indicates a potential short circuit in the boiler water temperature sensor or burner control unit. Check the lead and dual sensor, and replace the sensor if necessary.
E
Edward PhillipsAug 27, 2025
How to fix Viessmann VITOCROSSAL 200 Boiler error F 82?
- R
  Richard HuntAug 27, 2025
  If your Viessmann Boiler is showing the error code F 82, there may be a short circuit in the flue gas temperature sensor (A or B) or the burner control unit. Check the lead and sensors (A and B), and replace the sensor if needed.
M
moorestephanieAug 28, 2025
What causes error code F 88 on a Viessmann VITOCROSSAL 200 Boiler?
- A
  Ana ThompsonAug 28, 2025
  If your Viessmann Boiler displays the error code F 88, it indicates a lead break in the boiler water temperature sensor or burner control unit. Check the lead and dual sensor; replace the sensor if required.
M
Mary MckinneySep 12, 2025
What to do if Viessmann Boiler air pressure switch shows no air pressure and the fan does not operate?
- S
  shawnlambertSep 12, 2025
  If the air pressure switch shows no air pressure and the fan does not operate on your Viessmann Boiler, replace the air pressure switch and ensure it is correctly connected or set.
T
Thomas HensonSep 12, 2025
What to do if Viessmann VITOCROSSAL 200 Boiler fan does not run?
- D
  Deanna LambertSep 12, 2025
  If the fan of your Viessmann Boiler does not run, check the cables. If the cables are faulty or broken, or the fan itself is faulty, replace the fan if required.
H
haley68Sep 4, 2025
What to do if Viessmann VITOCROSSAL 200 Boiler has no flame signal during the safety time?
- S
  Sara JohnsonSep 4, 2025
  If your Viessmann Boiler shows no flame signal during the safety time, and the ionisation flame monitor reports no flame signal, it could be due to several reasons: * The ionisation electrode may be incorrectly adjusted or the cable may not be plugged in. Adjust the ionisation electrode or plug in the ionisation electrode. * The ignition electrodes may be incorrectly adjusted. Adjust the ignition electrodes. * The insulation body of the ignition electrodes may be cracked. Replace the ignition electrodes. * The incorrect gas type may be selected. Adjust the gas type. * The gas train may not be opening. Check the gas train and replace it if required.
D
Diana KennedySep 2, 2025
What to do if Viessmann VITOCROSSAL 200 burner is OFF due to lack of gas?
- J
  John Johnson MDSep 2, 2025
  If the Viessmann Boiler burner is OFF due to a lack of gas, notify your gas supply company.

Viessmann VITOCROSSAL 200 Specifications

General

Model	VITOCROSSAL 200
Category	Boiler
Installation Type	Floor Standing
Heat Exchanger Material	Stainless Steel
Control	Vitotronic Control Unit
Boiler Type	Condensing
Efficiency	Up to 98%
Modulation	5:1
Max Flow Temperature	90°C
Fuel Type	Natural Gas

Summary

Service Instructions

Vitocrossal 200 Type CM2 Gas Condensing Boiler

Service instructions for the Vitocrossal 200 Type CM2 gas condensing boiler.

Safety Instructions

If You Smell Gas

Provides emergency procedures to follow if natural gas is detected.

If You Smell Flue Gas

Procedures for dealing with the detection of flue gas.

Commissioning, Inspection, and Maintenance

Steps – Commissioning, Inspection and Maintenance

Detailed list of steps for commissioning, inspection, and maintenance procedures.

Checking High Limit Safety Cut-out

Filling Heating System with Water

Starting the Heating System

Checking Gas Supply Pressure

Coding at Control Unit

Checking Gas Type

Procedure for determining and verifying the gas type used.

Conversion to Natural Gas LL

Conversion for 115 to 311 kW

Checking Static and Supply Pressure

Procedure for checking static and supply gas pressures.

Checking Supply Pressure

Procedure for checking the gas supply pressure under flow conditions.

Checking CO2 Content

Procedure for measuring and adjusting CO2 content in flue gas.

CO2 Test at Lower Output (87 kW)

CO2 Test at Upper Output (115-311 kW)

CO2 Test at Lower Output (115-311 kW)

Checking Ionisation Current

Procedure for checking the ionisation current of the burner.

Checking Ignition and Ionisation Electrodes

Procedure for checking ignition and ionisation electrodes for gap and damage.

Installing the Burner

Checking Gas Train Valves for Tightness

Procedure for checking gas train valves for leaks on 115-311 kW models.

Checking All Gas Connections for Tightness

Procedure for ensuring all gas connections are leak-tight.

Implementing Final Tests

Checking Water Quality

Procedure for checking and recording water quality parameters.

Checking Diaphragm Expansion Vessel and System Pressure

Procedure for checking the diaphragm expansion vessel and system pressure.

Air Pressure Switch

Fault Shutdown

Explains the conditions that trigger a fault shutdown via the air pressure switch.

Burner Control Unit

Display and Programming Unit

Overview of the burner control unit's display and programming interface.

Operating Display

Manual Mode and Service Display

DIP Switch Setting or Parameter Set

Guide to setting DIP switches and selecting parameter sets for burner output.

Fault Display

How the burner control unit displays faults and error codes.

Fault Memory

Troubleshooting

Diagnosis

Table of fault codes, system characteristics, causes, and measures.

Message Codes

List of message codes displayed by the unit and their interpretations.

General Process Errors

Control Unit

Adjusting Codes at the Control Unit

Instructions for adjusting coding addresses for different burner outputs.

Commissioning/Service Report

Setting and Test Values

Table for recording static pressure, CO2, O2, CO, temperature, and draught values.

Water Quality Requirements

Prevention of Damage Due to Scaling

Measures to prevent scale build-up on heating surfaces according to VDI guideline.

Prevention of Damage Due to Corrosion

Specification

Gas Boiler, Category I2ELL

Matrix Radiant Burner

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