Viessmann VITOCROSSAL 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2B, 87 to 311 kW
Gas condensing boiler with MatriX radiant burner
6 bar
For applicability, see the last page
VITOCROSSAL 200
5677 612 GB 10/2016 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are intended exclusively for quali-
fied contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
■This appliance has not been designed to be oper-
ated by individuals (including children) with limited
physical, sensory or mental capacities or who are
lacking in the appropriate experience and/or knowl-
edge, unless they are supervised by a person with
responsibility for their safety or were instructed by
that person in the operation of this appliance.
!Please note
Children should be supervised.
Ensure that children never play with the appli-
ance.
Regulations
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■Codes of practice of the relevant trade associations.
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards.
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS Directive 1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Do not press any switches for lights or
electrical appliances.
■Close the gas shut-off valve.
■Open windows and doors.
■Remove all people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Shut off the electricity supply to the building
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threatening poisoning.
■Shut down the heating system.
■Ventilate boiler room.
■Close all doors in the living space.
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply (e.g. at the
separate fuse or a main switch) and check that it is
de-energised.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharges.
Before beginning work, touch earthed objects,
such as heating or water pipes, to discharge
static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components only with original
Viessmann spare parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5677 612 GB

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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Vitotronic control unit
codes
Setting the codes at the control unit ...................................................... 30
4. Burner control unit Burner control unit VUC 310 .................................................................. 31
■Display and programming unit ............................................................ 31
■Operating display ................................................................................ 31
■Info display/configuration display ........................................................ 32
■Resetting operating parameters to their delivered condition .............. 33
■Manual operation and service display ................................................ 34
Burner control unit flow chart ................................................................. 35
■Description of state: ............................................................................ 35
5. Troubleshooting Fault display ........................................................................................... 37
■Fault memory ...................................................................................... 37
Fault codes ............................................................................................ 37
■General process errors ....................................................................... 37
■Internal system faults .......................................................................... 40
Faults without fault display ..................................................................... 40
6. Parts lists Overview of assemblies ......................................................................... 41
Boiler assembly ..................................................................................... 42
Thermal insulation assembly ................................................................. 44
Miscellaneous assembly ........................................................................ 46
7. Component overview Overview of burner components ............................................................ 48
■Pressure-jet gas burner, type VMA III, 87 kW .................................... 48
■Pressure-jet gas burner, type VMA III, 115 to 311 kW ........................ 49
8. Function description Air pressure switch ................................................................................ 50
■Fan pressure monitoring function (LDW1) .......................................... 50
■Combustion chamber pressure monitoring function (LDW2) .............. 50
■Fan for burner 115 to 311 kW ............................................................. 51
9. Connection diagrams Burner control unit connection diagram ................................................. 52
10. Reports ................................................................................................................ 56
11. Specification ................................................................................................................ 58
12. Final decommissioning Final decommissioning and disposal ..................................................... 61
13. Certificates Declaration of Conformity ...................................................................... 62
Manufacturer’s certificate according to the 1st German Immissions
Order (BImSchV) ................................................................................... 62
14. Keyword index ................................................................................................................ 64
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Symbols
5677 612 GB
Information

6
Vitocrossal 200 CM2B 87 to 311 kW with permissible
operating pressure 6 bar (0.6 MPa).
Gas condensing boiler for natural gas E and LL, with
modulating MatriX radiant burner
Information
Product information
5677 612 GB
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting................................................................ 9
•2. Filling the heating system with water and venting......................................................... 9
•3. Filling the trap with water.................................................................................................. 9
••• 4. Commissioning the system............................................................................................... 9
•5. Checking the gas type....................................................................................................... 11
•6. Converting to natural gas LL............................................................................................ 11
•7. Reducing the operational output (if required)................................................................. 12
••• 8. Checking static pressure and supply pressure.............................................................. 13
••• 9. Checking the rotary damper setting................................................................................. 15
••• 10. Checking the CO2 content................................................................................................. 16
••• 11. Checking the CO content
••• 12. Checking the flue gas temperature
• • 13. Displaying the ionisation current..................................................................................... 19
• • 14. Shutting down the system................................................................................................. 20
• • 15. Opening the boiler door..................................................................................................... 20
• • 16. Cleaning the combustion chamber and heating surfaces............................................. 20
• • 17. Checking the gaskets and thermal insulation sections................................................. 20
• • 18. Checking all connections and the sensor well on the heating water side for
tightness............................................................................................................................. 21
• • 19. Removing the neutralising system, connecting the drain hose.................................... 21
• • 20. Cleaning and reconnecting the condensate drain system............................................. 22
• • 21. Checking the condensate drain and neutralising system (if installed)......................... 22
• • 22. Checking the burner gauze assembly.............................................................................. 23
• • 23. Checking the ignition electrodes and ionisation electrode........................................... 23
• • 24. Closing the boiler door...................................................................................................... 24
• • 25. Cleaning the burner........................................................................................................... 24
•26. Fitting the burner................................................................................................................ 25
• • 27. Checking the gas train valves for tightness.................................................................... 26
• • 28. Checking the filter element in the gas line...................................................................... 26
••• 29. Checking gas connections for tightness......................................................................... 26
• • 30. Checking the gaskets on the flue gas side...................................................................... 27
•31. Performing final checks..................................................................................................... 28
• • 32. Checking the water quality................................................................................................ 28
••• 33. Checking the safety valve function
• • 34. Expansion vessel .............................................................................................................. 28
• • 35. Checking the mixer for ease of operation and leaks...................................................... 28
••• 36. Checking the thermal insulation for firm seating
••• 37. Checking the installation room ventilation air apertures............................................... 29
•38. Instructing the system user.............................................................................................. 29
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•39. Operating and service documents................................................................................... 29
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5677 612 GB

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The high limit safety cut-out must not be set higher
than 110 °C; if required, set it to a maximum of 110 °C.
Control unit installation and service instructions
Filling the heating system with water and venting
Record the volume filled, water hardness and pH value
on page 56.
Note
Observe section "Water quality requirements" on
page 54.
Filling the trap with water
Fig. 1
1. Undo the trap and fill it with water. Otherwise flue
gas may escape.
2. Check that the condensate can drain freely.
3. Refit the trap.
Commissioning the system
Danger
CO build-up as a result of incorrect burner
adjustment can have serious health implications.
Always carry out a CO test before and after
work on gas appliances.
Control unit operating and service instructions,
and neutralising system operating instructions
Commissioning, inspection, maintenance
Checking the high limit safety cut-out setting
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A B
D
C
Fig. 2
01. Check the heating system pressure.
Permiss. operating
pressure
6 bar (0.6 MPa)
Minimum operating
pressure
0.5 bar (50 kPa)
Danger
If the operating pressure is too low, excess
temperatures in the flue system can cause
leaks. Escaping flue gas can cause life
threatening carbon monoxide poisoning.
Ensure the minimum operating pressure
with a minimum pressure switch.
02. For open flue operation: check that the ventilation
facility in the installation room is open.
03. Check the gas supply pressure.
04. Open the gas line shut-off valves.
05. Switch ON the mains isolator (outside the installa-
tion room).
06. Switch ON system ON/OFF switch B at the con-
trol unit. If fault indicator A on the control unit illu-
minates and display C on the burner control unit
flashes, first reset the system. To do this, press
reset button D on the burner control unit.
Note
The boiler can enter a fault state during commis-
sioning if the gas line carries insufficient gas. The
fault indicator on the control unit illuminates. Purge
the gas line again and reset the burner control
unit.
07. Adjust the codes on the boiler control unit in
accordance with the table on page 30.
Note
If the codes are not set, the boiler’s service life
and efficiency may be adversely affected.
Control unit installation and service instruc-
tions
08. Check the function of the neutralising system.
Neutralising system operating instructions
09. Check all gaskets and plugs, and retighten if nec-
essary.
Note
We recommend you check all connections on the
heating water side for leaks approx. every
500 hours run. See page 21.
10. Check the boiler door and flue gas cover a few
days after commissioning. In the case of leaks,
tighten the screws in the boiler door and flue gas
collector with 30 Nm.
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5677 612 GB