Viessmann Vitocrossal 200 CM2 500 Operating instructions

Service Instructions
VITOCROSSAL 200
5546 489 - 15 05/2021
for use by heating contractor
Vitocrossal 200
CM2 Series 400, 500 and 620
Gas condensing boiler with cylinder burner
Read and save these instructions
for future reference.
Please file in Service Binder
Heating input: 1445 to 2245 MBH
(423 to 658 kW)
Product may not be exactly as shown
IMPORTANT
H

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5546 489 - 15
Vitocrossal 200, CM2 400, 500 and 620 Service
Safety, Installation and Warranty Requirements
Safety
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
WARNING
Installers must follow local regulations with respect to
installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained
in this manual.
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to
Viessmann equipment.
For a listing of chemicals which
cannot be stored in or near the
boiler room, please see subsection
entitled “Mechanical room” in the
“Installation Instructions”.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Carbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.
For information pertaining to the
proper installation, adjustment, service
and maintenance of this equipment to
avoid formation of carbon monoxide,
please see subsection entitled
“Mechanical room” and “Venting
requirements” in the “Installation Instructions”.
Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Mechanical room” in the “Installation
Instructions”.
Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Connection”. All products of
combustion must be safely vented
to the outdoors.

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5546 489 - 15
Vitocrossal 200, CM2 400, 500 and 620 Service
Safety, Installation and Warranty Requirements (continued)
Safety
About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.
IMPORTANT
Warnings draw your attention to the presence of
potential hazards or important product information.
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious injury
or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
Fiberglass wool and ceramic fiber materials
WARNING
Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are known
to the State of California to cause cancer, birth defects
and other reproductive harm. Always use proper safety
clothing, respirators and equipment when servicing or
working nearby the appliance.
The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.
First aid measures
- If eye contact occurs, flush eyes with water to remove
dust. If symptoms persist, seek medical attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the person
to a dust free location.
- Eye irritation: If eyes become irritated, flush immediately
with large amounts of lukewarm water for at least 15
minutes. Eyelids should be held away from the eyeball
to ensure thorough rinsing. Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin. Wash area
of contact thoroughly with soap and water. Using
a skin cream or lotion after washing may be helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.

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5546 489 - 15
Vitocrossal 200, CM2 400, 500 and 620 Service
Table of Contents
Safety
General Information
Start-up
Commissioning, Inspection and
Maintenance
Page
Safety, Installation and Warranty Requirements..............2
About these Installation Instructions..............................3
Equipment.................................................................6
Product Information.....................................................6
Important Regulatory and Installation Requirements........7
Safety Instructions......................................................8
Target group..........................................................8
Regulations.............................................................8
If you smell gas......................................................8
If you smell flue gas................................................8
Working on the system.............................................8
Repair work............................................................8
Auxiliary components, spare and wearing parts...........8
Checking the high limit safety cut-out setting..............8
Filling the Heating System with Water...........................9
Filling Condensate Trap with Water...............................9
Removing Covers......................................................10
Burner Overview.......................................................11
Steps - Commissioning, Inspection and Maintenance.....12
Commissioning the system......................................12
Select the gas type...............................................12
Conversion to liquid propane gas (LPG)....................13
Conversion to natural gas (NG)................................14
Converting gas type on burner control unit................15
Altitude adjustment................................................15
Reducing operational input (if required).....................16
Checking the static and the supply pressure..............16
Supply pressure for NG and LPG..............................17
Checking the Rotary Damper Setting........................17
Checking the CO2level...........................................18
Preparing the test..................................................18
CO2test at the upper heating input..........................18
CO2test at the lower heating output........................19
Displaying the ionization current...............................19
Shutting down the system.......................................20
Opening the boiler door..........................................20
Separating the neutralizing system (if installed)
from the boiler and connecting the drain hose............21
Cleaning the combustion chamber and heating surfaces..21
Checking gaskets and thermal insulation parts...........21
Checking all connections for leaks............................21
Cleaning and reconnecting the condensate drain system..22
Checking the condensate drain and the neutralizing
system (if installed)................................................22
Check neutralization unit (if installed).......................22
Checking the cylinder burner assembly......................23
Checking the ignition and ionization electrodes..........24
Checking the 15A and 15B flue gas sensor...............25
Checking the 3A and 3B boiler temperature sensor....25
3A and 3B boiler temperature sensor description......26
Making the electrical burner connection.....................27
Cleaning the burner................................................28
Fitting the fan.......................................................28
Checking all gas connections for leaks......................29
Checking the Flue Side Gaskets/Seals.........................29
Flue side gaskets/seals............................................29
Checking the Diaphragm Expansion Vessel and
System Pressure.......................................................30
Check proper expansion tank and system pressure.....30
Water quality.........................................................30

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5546 489 - 15
Vitocrossal 200, CM2 400, 500 and 620 Service
Burner Service
Boiler Control
Burner Control Unit
Flow Diagram
Connection Diagram
Troubleshooting
Parts
Specifications
Inspection and Maintenance
Table of Contents
Further Details Regarding the Individual Steps..............31
Fan pressure monitoring function
(air pressure switch 1) ..........................................31
Combustion chamber pressure monitoring
(air pressure switch 2) .........................................31
Gas inlet pressure monitoring switch - GDW1...........32
Valve seat gas pressure monitoring switch - GDW2...32
Auxiliary low gas pressure switch...............................34
Burner Component Overview......................................35
CM2 pre-mix cylinder burner 400/500/620................35
Accessing the Burner.................................................36
Burner Control..........................................................36
Burner Control Coding Card.......................................37
Burner Control Programming Unit................................38
Gas Valve................................................................38
Ignition Unit.............................................................39
Ignition Cable...........................................................39
Motorized Burner Inlet Damper....................................40
Inlet Damper Servomotor...........................................40
Inlet Damper Linkage.................................................41
Plug Console with Relay.............................................41
Burner Fan...............................................................42
Burner Tube.............................................................42
Burner Door.............................................................44
Burner Door Refractory..............................................46
Further Installation and Initial Start Up Instructions.......47
Boiler Water Temperature Sensor................................47
Flue Gas Temperature Sensor.....................................48
Burner Control Unit...................................................49
Display and programming unit.................................49
Operating display...................................................49
Information and configuration display.......................51
Resetting Operating Parameters to their Factory Settings..53
Manual Mode and Service Display...............................53
Burner Control Unit Flow Diagram...............................54
Burner Control Unit Connection Diagram......................56
Faults......................................................................57
Fault display..........................................................57
Fault memory.........................................................57
Fault Codes..............................................................58
General process errors............................................58
Internal system fault...............................................61
Faults Without Fault Display.......................................61
Installation Fittings....................................................62
Parts Lists................................................................63
Technical Data.........................................................69
Cylinder Burner........................................................71
Maintenance Record..................................................72
Maintenance Schedule...............................................73
Page