Viessmann VITOCROSSAL 200 Bedienungsanleitung

Operating Instructions

VITOCROSSAL 200

5773 601 - 01 05/2014

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 illustrated.

Do not store or use gasoline or other

ﬂammable liquids in the vicinity of this

or any other appliance.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliances.

Do not touch any electrical switches,

do not use any phone in your building.

Immediately call your gas supplier

from a neighbor’s phone. Follow

the gas supplier’s instructions.

If you cannot reach your gas supplier,

call the ﬁre department.

Installation and service must be

performed by a qualiﬁed 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

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

Safety, Installation and Warranty Requirements

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).

General Information

WARNING

Installers must follow local regulations with respect

to installation of carbon monoxide detectors. Follow

the Viessmann maintenance schedule of the boiler

contained in “Service Instructions”.

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”.

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 sections entitled

“Mechanical Room” and “Venting

Connection” 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”.

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.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating Table of Contents

Safety, Installation and Warranty Instructions................2

About these Instructions.............................................4

For your Safety..........................................................4

Operation...............................................................4

Gas smell...............................................................4

Flue gas smell.........................................................4

Working on the equipment.......................................5

Combustion air and ventilation openings....................5

Carbon monoxide....................................................5

Dangerous conditions..............................................5

Frozen water pipe hazard.........................................5

Maintenance and cleaning........................................6

Regular maintenance and service..............................6

Technical Information..............................................6

Description................................................................7

Fuels.....................................................................8

Boiler control..........................................................8

Condensate disposal................................................8

Boiler location.........................................................8

Venting connection.................................................8

Optimum operation..................................................8

Operation..................................................................9

Starting the heating system......................................9

Separate heating system controls.............................9

Domestic hot water production.................................9

System shutdown...................................................9

Service Schedule......................................................10

Additional Maintenance Information............................11

Danger of freezing.................................................11

Long periods of shutdown......................................11

Water quality........................................................11

General Information

Safety

System Information

Service and Maintenance

Page

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

About these 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

CAUTION

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.

General Information/Safety

Incomplete combustion and poisonous gases result if the

fresh air intakes in the mechanical room are closed. Never

close these openings.

CAUTION

WARNING

Indicates an imminently hazardous situation which,

if not avoided, could result in death, serious injury

or substantial product/property damage.

Indicates an imminently hazardous situation which,

if not avoided, may result in minor injury or product/

property damage.

For your Safety

Operation

Before operating the boiler, make sure you fully

understand its method of operation. Your heating

contractor should always perform the initial start-up and

explain the system. Any warranty is null and void if these

instructions are not followed.

Gas smell

Follow the instructions on the front of the manual.

Flue gas smell

- Deactivate heating equipment.

- Open windows and doors.

- Inform your heating contractor immediately.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating Safety

For your Safety (continued)

Working on the equipment

All personnel working on the equipment or the heating

system must have the proper qualifications and hold all

necessary licenses.

Ensure main power to equipment, heating system, and

all external controls have been deactivated. Close main

gas supply valve. Take precautions in all instances to

avoid accidental activation of power during service

work.

Combustion air and ventilation openings

Ensure that combustion air openings and ventilation

air openings in the mechanical room are open.

Carbon monoxide

The U.S. Consumer Product Safety Commission

strongly recommends the installation of carbon

monoxide detectors in buildings in which gas-burning

equipment is installed. Carbon monoxide (CO) is a

colorless, odorless gas, which may be produced during

incomplete combustion of fuel and/or when the flame

does not receive an adequate supply of combustion air.

Carbon monoxide can cause severe personal injury or

loss of life.

Therefore, carbon monoxide detectors that are in

compliance with a nationally recognized standard

(e.g. ANSI/UL 2034-2002, CSA 6.19-01) should be

installed and maintained in buildings that contain

gas-burning equipment.

Note: Viessmann does not test any detectors and

makes no representation regarding any brand

or type of detector.

Dangerous conditions

- Deactivate main power immediately

- Close gas supply valve

Frozen water pipe hazard

Your heating boiler is designed to provide a warm and

comfortable living environment. It is NOT designed to

ensure against freezing of water pipes.

The boiler is equipped with several safety devices that are

designed to shut down the boiler and to prevent it from

restarting in the event of various unsafe conditions.

If your boiler remains off for an extended period of time

during cold weather, water pipes may freeze and burst,

resulting in extensive water damage and conditions in

which mold could grow. Certain molds are known to

cause respiratory problems, as well as to pose other

serious health risks. In case of water damage, immediate

measures should be taken to dry out affected areas as

quickly as possible to prevent mold from developing.

If your home will be unattended for an extended period

of time during cold weather, you should...

- Shut off the water supply to the building, drain the

water pipes and add an antifreeze for potable water

to drain traps and toilet tanks. Open faucets where

appropriate.

Or...

- Have someone check the building frequently during

cold weather and call a qualified service agency if

required.

Or...

- Install a reliable remote temperature sensor that will

notify somebody of freezing conditions within the

home.

WARNING

Failure to protect against frozen pipes could result in

burst water pipes, serious property damage and/or

personal injury. Boiler may shut down. Do not leave

your home unattended for long periods of time during

freezing weather conditions without turning off the

water supply and draining water pipes or otherwise

protecting against the risk of frozen pipes.

IMPORTANT

Keep all literature in a safe place at the installation site.

Contact Viessmann for additional copies.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

For your Safety (continued)

Safety

WARNING

The boiler must not be located in areas or rooms

where chemicals are stored, or aggressive vapors

from (i.e. bleach, hair spray, methyl chloride, carbon

tetrachloride or perchloroethylene) or high dust levels

or humidity levels are present. Heat exchanger

corrosion might occur and reduce the lifetime of the

boiler significantly. If above criteria are not properly

observed and boiler damage results, any warranty on

the complete boiler and related components will be

null and void.

WARNING

Improper installation, adjustment, service, or

maintenance can cause flue products to flow into

living space. Flue products contain poisonous carbon

monoxide gas which can cause nausea or asphyxiation

resulting in severe personal injury or loss of life.

WARNING

As there are no user-serviceable parts on the boiler,

burners or control, the end-user must not perform

service activities of any kind on system components.

Failure to heed this warning can cause property

damage, severe personal injury, or loss of life.

WARNING

Do not use this boiler if any part has been under, or

exposed to water. Immediately call a qualified heating

contractor to inspect the boiler and to replace any part

of the control system and any gas control which has

been under, or exposed to, water.

Maintenance and cleaning

Regular inspection and service by a qualified heating

contractor is important to the performance of the

Viessmann CM2 boilers. Neglected maintenance

impacts on warranty; regular inspection ensures

clean, environmentally friendly and efficient operation.

We recommend a maintenance contract with a

qualified heating contractor.

Regular maintenance and service

The entire heating system must be cleaned and

serviced on a regular basis by a qualified heating

contractor or service agency to ensure reliable,

energy-efficient, and environmentally friendly

operation.

The build-up of soot on the heat exchanger raises

the flue gas temperature and reduces efficiency.

Indirect-fired domestic hot water storage tanks (if

installed) should be serviced within two years (at

most) of the installation date, and regularly thereafter.

For an overview of scheduled service procedures,

please see section entitled “Service Schedule” on

page 10 of this manual.

The owner or dedicated personnel should perform

the checks outlined in the Service Schedule to ensure

proper operation of the heating system.

IMPORTANT

Keep boiler and boiler room clear and free from combustible

materials, gasoline and other flammable vapors and liquids.

Do not obstruct the flow of combustion and ventilation air.

All inspection, maintenance and service must be performed

by a qualified heating contractor.

IMPORTANT

Technical information

Literature applicable to the Vitocrossal 200, CM2 boiler:

- Installation Instructions

- Service Instructions

- Operating Instructions

- Combustion air intake adaptor Installation Instructions

Keep all literature in a safe place at the installation site.

Contact Viessmann for additional copies.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

Description

System Information

The Viessmann Vitocrossal 200, CM2 boiler series is

CSA certified for Canada, is constructed in compliance

with CSA B51 Standard and carries Canadian Registration

Numbers.

The boiler is suitable for a maximum operating pressure

of 75 psig and a maximum boiler water temperature of

210° F (99° C).

The Vitocrossal 200 boiler must only be installed in

closed loop hot water heating systems using a precharged

membrane expansion tank.

Legend

V Vent pipe connection

D Drain

CD Condensate drain

BR Boiler return

BTS Boiler water temperature sensor

BS Boiler supply

SH Female connection NPT ½ in. for pressure gauge

CA Combustion air pipe connection

SS Safety supply; pressure relief valve, air vent,

low water cut-off

The proper burner size must be verified and the burner

must be adjusted so that the maximum input of the

appropriate boiler size is always observed and adjusted.

The gas burner must be installed according to the

instructions supplied by the burner manufacturer.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

Description (continued)

System Information

Fuel(s)

Natural gas or liquid propane gas.

Boiler control

The Vitocrossal 200 boiler series is operated with

a Vitotronic control and microcomputer indoor/

outdoor control system for boiler operation without

low temperature limit. The control system must be

programmed for this type of operation by the installer.

Control instructions supplied with boiler control.

CAUTION

The boiler room must be safe from frost and be

properly ventilated.

Condensate disposal

During the operation of the Vitocrossal 200 boiler,

the amount of condensate as per the diagram can be

expected.

The values given are approximate amounts occurring

under practical conditions. Not included in the chart is

the amount of condensate occurring in the vent pipe and

chimney system. The condensate from the chimney

system can be collected together with the condensate

from the heating boiler and be disposed of into a floor drain.

The condensate occurring will have a pH value between

3 and 4. If local building requirements demand neutralizing

the condensate before disposal, contact Viessmann

Manufacturing Company Inc. for a correctly sized

neutralization tank. The treated condensate will show pH

values of between 6.5 and 9 and can then be disposed of

into the waste water system.

Boiler location

The boiler must not be installed in rooms or areas where

halogenated hydrocarbons are present in the combustion

air, such as barber shops and beauty salons, printing

shops, chemical cleaners, laboratories etc.

Vitocrossal 200 boiler efficiency dependent on system

heating water return temperatures and load conditions

Venting connection

A large amount of water vapor contained in the flue gases

of condensing boilers condenses. The condensate pH

value is between 3 and 5.5. The flue gas temperatures

depending on the boiler water temperature may be

between 77° F (25° C) and 257° F (125° C).

The manufacturer of the chimney system or venting

system has to properly design the venting system as well

as select proper materials.

If there are any questions in regards to the neutralization

of the condensate and/or to the venting of this boiler

series, contact your local Viessmann Sales Representative.

Optimum operation

To ensure optimum operation of your heating system do

the following:

Keep the boiler and the boiler room clean and free

of dust and dirt.

Ensure proper and adequate system pressure by

occasionally checking the pressure gage.

Have a qualified heating contractor service and

maintain your heating system on a regular basis.

See Service Schedule starting on page 10 for details.

Amount of condensate

Boiler water return temperature

Flue gas temperature gross

Flue gas temp.

at full input

at partial load

Flue gas temp.

Amount of

condensate

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating System Information

Operation

System shut-down

The boiler controls monitor the operation of your heating

system in conjunction with installed system controls (if

applicable) based upon indoor/outdoor control, setback

programming and other settings. Please refer to the

respective documentation of the boiler controls, or other

system controls, to make adjustments.

Deactivate main power switch and all additional switches

controlling additional pumps or controls, including main

switch for burner. Close all valves in the system.

Read the operating instructions supplied with the Vitotronic

control, as well as Operating Instructions of the gas burner

before deactivating or activating the heating system.

IMPORTANT

Separate heating system controls

In case additional controls are installed in the boiler room,

e.g. control aquastats, mixing valves, controls etc., please

observe their respective operating instructions.

Domestic hot water production

The Vitocrossal 200 boiler may be used to supply

domestic hot water heating by means of an indirect-fired

hot water storage tank. The appropriate connections

to the boiler must be made, as well as the correct size

circulating pump must be used. The control circuit to

provide domestic hot water is already provided within

the Vitotronic control.

AON indicator (green)

BFault indicator (red)

CEmissions test switch (only for service purposes)

DON/OFF switch

EMCB/fuses

Starting the heating system

Ask your heating contractor about the following:

Boiler and relevant control unit type

Level of the required system pressure

Position of the pressure gauge, shutoff valve,

gas shut-off valve, ventilation apertures

1. Check the heating system pressure at the pressure

gauge. If the pressure of the heating system is too

low, top up the water or notify your heating

contractor.

2. Open the gas shut-off valve.

3. Switch ON the power supply, e.g. at a separate MCB/

fuse or a mains isolator.

4. Switch the ON/OFF switch ON (see diagram).

After a short time, the standard menu is displayed

(see page 13) and the green ON indicator illuminates.

Your heating system and, if installed, your remote

controls are now ready for use.

5773 601 - 01

Vitocrossal 200, CM2 400, 500 and 620 Operating

Service Schedule

Service and Maintenance

Frequency Performed by Service

Monthly Owner /

Operator

Check the system pressure frequently.

Ensure proper operation of the boiler control.

Inspect all seals; retighten or replace as necessary.

Ensure an adequate supply of combustion air/ventilation air into and out of

the mechanical room is maintained.

Ensure that nothing obstructs the flow of combustion - ventilation air, and no

chemicals, garbage, gasoline, combustible materials, flammable vapors, or liquids

are stored, not even temporarily, in the vicinity of the boiler.

Check for water on the floor from the discharge pipe of pressure relief valve

or any other pipe, pipe joint, valve, or air vent.

Test pressure relief valve and check for proper operation.

Check all operational high limits for proper operation.

Check for proper operation of the condensate neutralization system (if used).

Test pressure relief valve and check function.

Check the condition and fill status of the neutralization media.

Check the pH value of the flue gas condensate.

Check for moisture/water on vent pipe joints and appearance of ice on the vent

pipe or chimney outlet in the winter time.

Annually Owner /

Operator

Ensure service work/test is conducted at least annually by a qualified heating

contractor, and that any deficiencies are corrected immediately.

Heating

Contractor

Test functionality of safety high limits.

Test burner with burner accessories according to the corresponding maintenance

checklist.

Test and establish proper chemical makeup of system water.

Check flue pipe condition, chimney connection and chimney itself.

Check pressure relief valve and system pressure, and verify proper operation.

Check heating pipe joints, valves, air vents, etc. System leaks must be corrected

immediately to avoid further defects. The cause of defect must also be determined

in order to avoid further problems.

Check for proper combustion air supply and ventilation of boiler / mechanical room.

Check for combustible materials or chemicals stored too close to the boiler.

Test high limits by dialing lower settings, switching burner on/off. If low water

cut-off is installed, check and verify proper function according to manufacturer’s

instructions.

The following is an overview of scheduled service steps.

Regular service work ensures reliable, energy-efficient, and environmentally friendly operation.

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