Viessmann Vitoplex 100-LS SXD Service manual

Operating and service instructions
for contractors
VIESMANN
Vitoplex 100-LS
Type SXD, 0.26 to 0.7 t/h
Oil/gas low pressure steam boiler
Permissible operating pressure 1 bar (0.1 MPa)
VITOPLEX 100-LS
5692729 GB 3/2019 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 exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■Pressure Equipment Directive
■Health and Safety at Work Act (BetrSichV) [Ger-
many] and extended technical rules for operational
safety (TRBS)
■Country-specific safety regulations for the installation
site
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
Safety instructions for working on the system
Commissioning
Note
Unpleasant odours may develop during commission-
ing. Ensure the installation room is well ventilated.
Before working on the system
■Close the fuel shut-off valve and secure against
unintentional reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer 'live'.
■Safeguard the system against reconnection.
Hot surfaces
Danger
Hot surfaces can lead to burns. Never touch hot
surfaces, e.g.
■Steam pipes
■Hot water pipes
■Cleaning apertures and closures on the boiler
system
■Boiler doors, as well as components behind
the doors
Observe occupational safety. Wear protective
clothing where necessary.
Electrostatic discharge
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5692729

3
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.
Dismantling and disposal
When dismantling and disposing of thermal insulation
materials and gaskets on the gas side, observe the
applicable safety regulations.
The product and its components must be disposed of
according to local environmental regulations.
This applies in particular to the disposal of thermal
insulation materials and gaskets/seals on the gas side.
Safety instructions for operating the system
General
The materials included in the product pose no threat to
health during operation.
If you notice oil leaks or the smell of gas
Danger
Escaping fuel can lead to explosions which may
result in very serious injuries.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the quick-acting fuel valve and shut-off
valve.
■Ventilate the boiler house.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the system.
■Ventilate the installation site.
Draining hot water
!Please note
The blow-down and TDS water from boiler sys-
tems can reach temperatures of over 100 °C.
Before draining water into the sewage system,
allow it to cool to a temperature of < 35 °C. If
necessary, consult the local water board.
Draining condensate from the flue gas side
!Please note
When starting up the boiler system, or under
certain operating conditions, condensate may
build up in the flue passes, the flue gas collector
and the downstream flues, including the chim-
ney.
The condensate must be drained away safely by
means of suitable installation measures put in
place by the system installer.
Subject to the regulations in the country concerned,
this condensate may need to be neutralised. In such
cases, consult the local water board or the body
responsible for issuing permits.
General information
Shut down the boiler immediately if there is any
safety-related damage.
Observe safety-related instructions.
After an accident, the condition of the system must not
be changed before the investigation takes place,
unless necessary in order to rescue people or prevent
further damage.
Only authorised personnel are permitted to enter the
boiler house.
Keep the boiler house clean at all times.
Do not store anything in the boiler house.
Keep exits clear.
Never use the boiler house or system components as
a drying area.
The operating personnel must log the following:
■Settings
■Readings
■Faults
■Replacement of spare parts
■Repairs
Any defects must be dealt with immediately by trained
personnel, e.g.:
■Abnormalities on weld seams
■Leaks
■Heavy corrosion
■Faulty instrument displays
■Noise in the boiler
Safety instructions
Safety instructions (cont.)
5692729

4
Faults and defects that cannot be remedied locally
must be reported to the manufacturer. Protect all boiler
parts and control equipment from rain, water leaks and
expelled steam.
Safety instructions
Safety instructions (cont.)
5692729

5
1. Information Symbols ................................................................................................. 6
Note ....................................................................................................... 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
Spare parts lists ..................................................................................... 7
2. Operating information Shutting down the system ...................................................................... 8
■Brief interruptions of operation ........................................................... 8
■Longer interruptions of operation ........................................................ 8
Maintenance instructions ....................................................................... 8
3. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
4. Troubleshooting Diagnostics ............................................................................................ 19
5. Water quality Water quality according to EN 12953-10 ............................................... 21
■Boiler feedwater requirements ............................................................ 21
■Boiler water requirements ................................................................... 21
6. Checklist Recommendations for operation, maintenance and testing in accord-
ance with EN 12953-6 ........................................................................... 22
■Checklist for boiler system: Steam boiler ........................................... 22
Scope and duration of testing ................................................................ 22
■Note .................................................................................................... 22
7. Commissioning/service
reports
Fill and top-up water table ..................................................................... 23
Maintenance/service report ................................................................... 23
8. Specification ................................................................................................................ 25
9. Declaration of Conformity ................................................................................................................ 26
10. Keyword index ................................................................................................................ 27
Index
Index
5692729

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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
Note
All diagrams in this document are schematic, illustra-
tive examples.
Intended use
Note
Applies to the product including all components
1. Operate under defined Viessmann general and
operating conditions (standard conditions) for
Vitoplex steam boilers and accessories, e.g. tem-
perature range, min./max. humidity, air pressure,
etc.
2. Use the specified equipment and auxiliary materi-
als (lubricants, spare and wearing parts, etc.)
3. Use defined fuels.
4. Read, observe and comply with associated product
documentation, e.g. technical guides, installation/
service/operating instructions.
5. Only install and operate in heating systems as per
EN 12953 and 14394.
6. Only use for steam generation or water heating.
Information
Symbols
5692729
Information

7
7. Only use for heating water according to EN 12953,
TRD 611 and 612, and VdTÜV/AGFW datasheet
(ΤCh 1466/FW510).
8. Equip for local operation according to regulations
specific to the country and site.
9. Fixed installation
10. Use only components approved for the specific
system.
Note
Any use not complying with the above points will be
deemed to be inappropriate.
Manufacturer approval
Any usage not as intended must first be approved by
the manufacturer.
Exclusion of liability
■Inappropriate use without manufacturer approval
■Incorrect use of the steam boiler or its components
■Incorrect operation
■Modification of system components not complying
with their intended function
Product information
Vitoplex 100-LS, type SXD
■Fuels: Fuel oil and natural gas
■Steam output 0.26 to 0.7 t/h
■Permissible operating pressure up to 1 bar (0.1 MPa)
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Intended use (cont.)
5692729
Information

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Brief interruptions of operation
If you temporarily do not wish to use your boiler sys-
tem, maintain the boiler water temperature at 95 °C to
prevent corrosion through ingress of oxygen into the
boiler water.
Longer interruptions of operation
Shut down your heating system completely if it will not
be needed for longer periods (several months).
■Before taking the boiler system out of use for a lon-
ger period, we recommend you take certain steps,
e.g. protecting the system against frost or preserving
the heating surfaces.
■To preserve the heating surfaces, first thoroughly
clean the surfaces on the flue gas side. Then pre-
serve these surfaces with a preserving oil/graphite
mixture.
■To protect the water side, we recommend flooding
the boiler with degassed, oxygen-free and treated
water with low salt content and added oxygen bind-
ers (e.g. sodium sulphite). Then close the steam
shut-off valve.
Check the concentration of the oxygen binder at
least every month and replenish if required. When
doing this, ensure that the binder is well mixed with
water inside the boiler.
■Another option is that of dry preservation, which is
recommended for shutdown periods of longer than
4 weeks.
■When there is a risk of frost, drain the boiler and the
heating system via the drain valve. Open the shut-off
control valve as well as the air vent valves.
Maintenance instructions
We recommend having the boiler system serviced reg-
ularly to ensure fault-free, efficient and environmentally
responsible operation.
The boiler should be cleaned regularly to prevent the
flue gas temperature rising with increasing contamina-
tion, which leads to higher energy consumption.
We recommend the installation of a flue gas thermom-
eter. Monitoring the flue gas temperature highlights
incorrect burner adjustment and the level of boiler con-
tamination.
Excessive flue gas temperatures through contamina-
tion or altered burner adjustment reduce efficiency.
Where necessary, clean the boiler or adjust the burner
settings.
Operating information
Shutting down the system
5692729
Operation

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Commissioning steps
Inspection steps
Maintenance steps Page
• • 1. Adjusting the pressure regulator and safety pressure limiter....................................... 10
• • 2. Commissioning the system............................................................................................... 10
•3. Notice of completion.......................................................................................................... 11
•4. Shutting down the system................................................................................................. 11
• • 5. Closing the draught stabiliser (if installed)..................................................................... 11
•6. Opening the boiler door and cleaning cover................................................................... 11
•7. Removing and cleaning the turbulators........................................................................... 12
•8. Cleaning the heating surface, flue outlet and flue.......................................................... 13
• • 9. Checking all gaskets and packing cords on the flue gas side
•10. Checking the thermal insulation components on the boiler door
•11. Inserting the turbulators.................................................................................................... 14
•12. Securing the boiler door and cleaning cover.................................................................. 14
•13. Checking the water chamber for deposits....................................................................... 15
•14. Cleaning the multiple level electrode............................................................................... 15
•15. Cleaning the water level indicator.................................................................................... 16
•16. Checking the hydraulic connections for leaks................................................................ 16
• • 17. Cleaning the sight glass in the boiler door...................................................................... 16
• • 18. Checking the Vitoair draught stabiliser (if installed)...................................................... 17
• • 19. Adjusting the burner.......................................................................................................... 17
• • 20. Checking the safety valve................................................................................................. 17
••• 21. Checking the pressure switch function........................................................................... 17
• • 22. Checking the safety and control equipment
•23. Checking the pressure regulator, safety pressure limiter and temperature
controller (standby)............................................................................................................ 17
•24. Checking the water quality................................................................................................ 17
• • 25. Checking the thermal insulation
• • 26. Checking the installation room ventilation
• • 27. Checking the flue for tightness
•28. Operating and service documents................................................................................... 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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1. Set the safety pressure limiter response pressure a
little higher than the setting of the pressure regula-
tor.
2. Secure the protective cap again on the safety pres-
sure limiter to prevent any unauthorised adjust-
ment at a later time.
3. During commissioning, adjust the pressure regula-
tor to the required operating pressure.
Never adjust the pressure regulator again after
this.
Note
Pressure regulators have one setting screw for the
switching point (e.g. 0.45 bar/45 kPa) and one for
the switching differential (e.g. 0.02 bar/2 kPa). This
means that the pressure regulator starts the burner
at 0.43 bar/43 kPa and shuts it down at 0.45 bar/
45 kPa.
Commissioning the system
According to the German Operational Safety Ordi-
nance, steam boilers with a safety pressure in excess
of 0.5 bar/50 kPa must be supervised. In accordance
with conformity assessment diagram no. 5 of the Pres-
sure Equipment Directive, these boilers must be
classed as category III. Prior to commissioning, the
system must be tested by an approved inspection
body (e.g. TÜV [Germany]).
Details provided by the burner manufacturer and
regarding accessories
01. Open the boiler door.
02. Check that the turbulators are fully inserted into
the hot gas flues (see page 14).
03. Check that the ventilation air aperture in the instal-
lation room is open.
04. Check the function of the water treatment system.
05. Fill the steam boiler with treated water higher than
the low water indicator level.
See manufacturer's documentation for the
burner.
Note
Only operate steam boilers with suitable water.
For water quality requirements, see from
page 21.
06. Check all fitted components, such as pipework,
valves, controllers, pumps, etc. for function and
leaks.
07. Check the oil level or the gas supply pressure.
08. Open the flue gas damper (if installed).
09. Check that the cleaning aperture on the flue outlet
is closed.
10. Open the shut-off valves in the oil lines (at the
tank and filter) or the gas shut-off valve.
11. Switch ON the mains isolator, the switch for the
feedwater pump and the burner ON/OFF switch, in
that order.
Burner manufacturer's operating instructions
12. Start the boiler with a low heating output (burner
stage 1 or partial load). Slowly ramp the burner up
to the required operating pressure.
13. Slowly open the steam valve after the required
operating pressure has been reached.
14. Only then should the full burner load be enabled.
15. While the system heats up, check the correct func-
tion of all control and safety equipment.
16. Observe the pressure and temperature measuring
devices.
17. Check the covers for leaks and retighten if neces-
sary.
18. Check the boiler door and cleaning cover for leaks
after approx. 50 hours run. Tighten the screws.
Commissioning, inspection, maintenance
Adjusting the pressure regulator and safety pressure limiter
5692729

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Note
We recommend that you operate the boiler constantly
at the required operating pressure. The ongoing opera-
tion of the boiler at pressure is harmless, even if no
heat demand occurs for a longer period of time. In sys-
tems comprising several boilers, one of which is con-
stantly only used as a standby boiler, operating mode
changeover should take place at longer intervals. For
example, during the annual inspection of the entire
system.
Notice of completion
Within 4 weeks of the combustion equipment being
commissioned, the operator must notify the local flue
gas inspector accordingly [check local regulations].
Shutting down the system
Danger
Opening the boiler connections and apertures
whilst the boiler is under pressure can lead to a
high risk of severe personal injury.
Only open the connections on the water side
and steam side, as well as the inspection ports,
after the boiler has been completely depressur-
ised.
!Please note
Negative pressure in the DHW cylinder can
cause material damage.
The air vent valve must always be open when
draining the DHW cylinder with a suction pump.
1. Close the shut-off valves in the oil lines (at the oil
tank and filter) or the gas shut-off valve.
2. Switch OFF the burner and the feedwater pump.
Pull the plug-in connector from the burner.
3. Isolate the system from the power supply.
4. Close all valves.
Closing the draught stabiliser (if installed)
1. Start the burner. 2. Shut the system down while pre-purge is active.
The control disc is then closed.
Opening the boiler door and cleaning cover
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
Note
On gas burners, remove the gas supply pipe.
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5692729

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4x
Fig. 1
Removing and cleaning the turbulators
A
Fig. 2
Remove turbulators A without force; for this, use the
turbulator extractor, which is part of the cleaning equip-
ment.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover (cont.)
5692729

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A B
Fig. 3
1. Clean flues A and combustion chamber B with
cleaning equipment and remove combustion resi-
dues.
C
Fig. 4
2. Remove combustion residues from the flue and
flue outlet C.
Checking all gaskets and packing cords on the flue gas side
Checking the thermal insulation components on the boiler door
Commissioning, inspection, maintenance
Cleaning the heating surface, flue outlet and flue
5692729

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!Please note
Burner adjustments and specific system condi-
tions can cause the turbulators to move forward,
which may result in them being burnt. This can
also lead to damage to the thermal insulation on
the boiler door.
Before insertion, the turbulators must be slightly
bent (see steps).
A
10°-15°
¾¼
B
Fig. 5
1. Push turbulators A approx. ¼ of their length into
secondary hot gas flues B.
2. Bend turbulators approx. 10 - 15°.
3. Insert the turbulators into the secondary hot gas
flues as far as they will go. At the same time, check
the pre-tension.
Note
Turbulators must not be able to be pulled from the
secondary heating pipes easily.
Securing the boiler door and cleaning cover
Note
Mount the gas supply pipe on gas burners.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
A
4x B
Fig. 6
Commissioning, inspection, maintenance
Inserting the turbulators
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Torque
Boiler door A25 Nm
Screws for cleaning cover
B
7 Nm
Checking the water chamber for deposits
A
Fig. 7
1. Open hand hole cover A.
2. Fully drain the boiler.
3. Clean the water chamber (hose it out) and remove
deposits via the blow-down valve and drain outlet.
If hard deposits have formed which cannot be
removed by hosing down, carry out a chemical
cleaning process with added descaling agent.
4. Clean the sealing faces of closures and fit new
gaskets. Tighten new gaskets after commissioning
and check again after 24 hours.
Torque settings for closure gaskets
System size Gasket Torque
SXD size 1 (170 kW) HL gasket 100 x 150
1 x M16
80 Nm
SXD size 2 - 6 (285 - 1450 kW) HL gasket 150 x 200
1 x M20
100 Nm
Cleaning the multiple level electrode
B
C
A
Fig. 8
1. Remove electrode A.
2. Clean electrode tips C.
3. Clean the sealing faces and use a new gasket B
(see standard EN 1591).
4. Install the electrodes and carry out a safety test in
line with the manufacturer's instructions.
5. Retighten new gaskets after commissioning.
Commissioning, inspection, maintenance
Securing the boiler door and cleaning cover (cont.)
5692729

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A
Fig. 9
1. Blow through the water level indicator.
2. Remove upper locking screw A and clean the
water level indicator with a brush.
See documentation for the water level indi-
cator.
Checking the hydraulic connections for leaks
Checking all connections on the water and steam side, as well as the sensor well and the inspection
ports, for leaks after filling the boiler
A
Fig. 10
1. Each time inspection ports have been opened:
Clean the sealing face.
2. Replace the gasket.
3. Retighten all covers after commissioning.
4. For testing the sensor well, remove cover A.
Cleaning the sight glass in the boiler door
Fig. 11
Check the gaskets and hose connection for leaks.
Commissioning, inspection, maintenance
Cleaning the water level indicator
5692729

17
Release the latch on the control disc. The control disc must swing freely during burner oper-
ation.
Adjusting the burner
Burner manufacturer’s details During adjustments, observe the minimum heating out-
put. Set the minimum heating output for the base load
stage according to the actual chimney conditions.
Checking the safety valve
Manufacturer's details Raise the operating pressure to the response pressure
or manually vent when 85 % of the response pressure
has been reached.
Checking the pressure switch function
Installation instructions in the "pressure switch
set"
Checking the safety and control equipment
Checking the pressure regulator, safety pressure limiter and temperature
controller (standby)
Check the pressure regulator, safety pressure limiter
and temperature controller (standby) for function and
correct adjustment.
Set the temperature controller (standby) to at least
95 °C.
Checking the water quality
Observe the instructions in chapter "Water quality
requirements".
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table on
page 23.
The total hardness of the feed and top-up water must
not exceed the total of alkaline earths of 0.015 mmol/l.
The pH value should be higher than 9.
Checking the thermal insulation
Checking the installation room ventilation
Commissioning, inspection, maintenance
Checking the Vitoair draught stabiliser (if installed)
5692729

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Operating and service documents
1. Complete and detach the customer registration
card:
■Hand the system user this part for safekeeping.
■Retain the heating contractor's part.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation and, therefore, do not need to
be retained.
Commissioning, inspection, maintenance
Checking the flue for tightness
5692729

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Fault Cause Action
Burner does not start. No power Switch ON the mains isolator.
Safety chain activated. Check safety equipment.
Burner fault indicator illuminates Press reset button on the burner
control unit.
Fuel supply interrupted Open shut-off valves in the fuel sup-
ply line and filter.
Remedy other faults in accordance with the burner manufacturer's in-
structions.
Oxygen corrosion (water side) Topping up with unsuitable water Check water treatment system and
injection system in accordance with
VdTÜV guideline.
Boiler is switched off every day. Switch to standby (95 °C) instead of
a complete shutdown.
Excessive flue gas temperature Heat transfer is reduced by contam-
ination on the flue gas and water
sides
Clean boiler.
The rated boiler heating output is
exceeded.
Check burner heating output.
Turbulators missing or incorrectly
fitted.
Maintenance and installation: See
page 12 and 14.
Discharge from safety valve. Discharge pressure does not match
system pressure.
Check the operating pressure with a
suitable pressure gauge.
Valve seat contaminated Clean valve seat.
Water trap pipe (upstream of pres-
sure regulator) clogged up
Clean pipes.
Boiler produces wet steam Excessive boiler water alkalinity Regularly blow-down the boiler and
install a TDS unit if required; treat
water according to EN 12953. Drain
the downstream steam line.
Water level set too high Check boiler water and feedwater
daily. Check electrode length.
Steam knocking inside boiler Feedwater not fed in at the feedwa-
ter connector
Connect feedwater line to the correct
connector.
Steam knocking inside the conden-
sate tank
The check valve in the feedwater
line is missing or faulty.
Install or clean check valve (observe
flow direction)
Steam trap in the system is faulty. Identify and repair faulty steam trap.
U-bends buckle Reduce steam pressure.
Boiler water level too high Steam distributor above the boiler is
not adequately drained.
Install a steam trap.
Troubleshooting
Diagnostics
5692729
Diagnosis

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Fault Cause Action
Water level limiter switches off. Shut-off valve in the feedwater line
is closed
Open the shut-off valve.
No feedwater in the condensate
tank
Check mains water connection.
Faulty feedwater pump or water lev-
el controller
Determine cause of water level con-
troller fault using the controller instal-
lation instructions.
Severe water level fluctuations
through excessive alkalinity
Drain water from boiler and conden-
sate tank.
If a TDS valve is fitted, increase de-
salination rate.
Refill with treated water.
Blow-down more frequently. Check
water treatment system.
Troubleshooting
Diagnostics (cont.)
5692729
Diagnosis