Viessmann Vitoplex 100-LS SXD User manual

Installation 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
5592837 GB 3/2019

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 must only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The commissioning must only be carried out by
trained specialist personnel in accordance with the
Viessmann operating and service instructions.
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
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.
Safety instructions
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1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
■System examples ............................................................................... 5
Note ....................................................................................................... 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
Anti-vibration supports ........................................................................... 6
3. Installation sequence Boiler positioning and levelling .............................................................. 7
Connection on the water and steam side .............................................. 8
Connecting the flue gas side ................................................................. 9
Fitting the thermal insulation .................................................................. 10
■Boiler shell thermal insulation ............................................................. 10
■Front rails and front thermal insulation ............................................... 11
■Back rails and back thermal insulation ............................................... 12
■Side and back panels ......................................................................... 13
■Front and cover panels ....................................................................... 14
Fitting the control valves ........................................................................ 14
■Water level indicator and fitting assembly (accessories) .................... 15
■Temperature controller and cover panels ........................................... 16
Installing electrodes (accessories) ......................................................... 17
■Multiple level electrode for operating pressure up to 0.5 bar (50 kPa) 17
■Combined level electrode for operating pressure up to 1.0 bar
(0.1 MPa) ............................................................................................ 19
TDS valve (manual) (accessories) ......................................................... 23
TDS unit (automatic) .............................................................................. 24
Installing the safety valve and testing for tightness ............................... 24
Mounting the burner ............................................................................... 25
Combustion chamber sight glass ........................................................... 25
■Mounting the combustion chamber sight glass .................................. 25
■Closing off the sight glass aperture on burners without ventilation
connection .......................................................................................... 26
Setting the pressure switch .................................................................... 27
■Pressure switch .................................................................................. 27
Adjusting the burner ............................................................................... 27
Commissioning information ................................................................... 28
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
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.
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.
Disposal of packaging
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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)
System examples
Available system examples: See www.viessmann-
schemes.com.
Note
All diagrams in this document are schematic, illustra-
tive examples.
Intended use (cont.)
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(50)
(300)
500
200 (100)
400 a
b
B
B
A
500
(400) 1000
C
1000
1000
Fig. 1
ABoiler
BBurner
CAnti-vibration supports
Note
Observe the stated dimensions to ensure straightfor-
ward installation and maintenance. Dimensions in
brackets are minimum clearances. Observe the clear-
ances with regard to the regulations applicable at the
installation site. Allow for equipment and accessories.
Maintain a side clearance of 1000 mm when using the
TDS unit.
Maintain length a in front of the boiler to enable the
removal of the turbulators or cleaning of the hot gas
flues.
An appropriate height must be provided above the
boiler for the installation or removal of the multiple
level electrode.
In the delivered condition, the boiler door is fitted so it
opens to the left. The hinge pins can be repositioned
so the door opens to the right.
Steam output t/h 0.26 0.44 0.7
amm 1200 1300 1400
bmm Observe the installed burner length
Height above the boiler mm 800 800 850
Anti-vibration supports
Recommendation
Use to provide vibration isolation and minimise trans-
mission of structure-borne noise.
Installation of anti-vibration supports
Manufacturer's installation instructions
Clearance dimensions
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D
Fig. 2
1. Insert adjusting screws D into the base rails.
Note
The adjusting screws and sight glass closure can
be found inside the combustion chamber.
2. Level the boiler horizontally. No special founda-
tions are required.
Note
We recommend positioning the boiler on anti-vibra-
tion boiler supports C (see Fig. 1), in which case
adjusting screws D will not be required.
Boiler positioning and levelling
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Danger
Opening the boiler connections and apertures
whilst the boiler is under pressure can lead to a
high risk of severe 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.
Note
Install all pipe connections free of load and torque
stress.
Thoroughly flush the system, especially when connect-
ing the boiler to an existing system.
EDBCBA
G
F
H
F
MLK N
Fig. 3
AFemale fitting assembly connection (with twin connector R ¾ × ½) R ¾
with 3 female connections for pressure gauge, pressure regulator and safety pres-
sure limiter
R ½
BConnector for water level limiter/water level control DN 100 PN 16
CSafety valve connector see page 24
DSteam connector for 0.26 t/h DN 100 PN 16
for 0.44 and 0.7 t/h DN 125 PN 16
EVent connector R ¾
FConnector for water level indicator DN 20 PN 40
GFemale vent connection R ¾
HSleeve for additional control equipment R ½
KFeedwater connector DN 40 PN 40
LDrain connector DN 40 PN 40
MFemale cleaning connection R 2
NConnector for TDS valve or TDS unit DN 20 PN 40
Connection on the water and steam side
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Ø10
ØD
2-3 x ØD
Fig. 4
1. Connect the flue outlet with the shortest possible
run to the chimney, maintaining a slight incline.
Steam output t/h 0.26 0.44 0.7
Flue gas con-
nection
7external
mm 200 200 250
2. Create a test port.
3. Seal in and thermally insulate the flue pipe (all con-
nections/joints must be gas-tight).
Connecting the flue gas side
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Note
All components required to fit the thermal insulation
can be found in the thermal insulation box.
Boiler shell thermal insulation
C B
A
D
1.
5.
3.
2.
6.
4.
Fig. 5
ABlack side outwards,
for 0.7 t/h: 2 pce
BSecure the pipe bends by their longest side to the
flanges, with gaskets.
DOnly if the TDS valve or TDS unit is fitted:
Secure the extension piece with gasket to the
flange; remove the blank flange to do so.
Note
Remove bag C containing the type plate and keep
safe. This will be required later (see page 13).
Fitting the thermal insulation
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Front rails and front thermal insulation
1.
2.
A
Fig. 6
AVitoplex logo
Note
Cut out the insulation mat for the front panel if
required. Secure the joints with spring hooks. Seal the
cut-outs with the glass fibre strips supplied.
Fitting the thermal insulation (cont.)
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Back rails and back thermal insulation
1.
3.
4.
5.
2.
Fig. 7
Note
Seal the cut-outs with the glass fibre strips supplied.
Compare the manufacturer's details on the back of the
boiler with the details on the type plate.
Fitting the thermal insulation (cont.)
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Side and back panels
A
2.
5.
4.
3.
1.
2.
Fig. 8
AAffix the type plate.
Note
Compare the manufacturer's details on the back of the
boiler with the details on the type plate.
If replacing the side panel on which the type plate is fit-
ted, please order a new type plate. State the serial no.
when ordering.
Fitting the thermal insulation (cont.)
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Front and cover panels
3.
1.
2.
Fig. 9
Fitting the control valves
Note
Carry out the installation in accordance with the
instructions supplied with the equipment.
Fitting the thermal insulation (cont.)
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Water level indicator and fitting assembly (accessories)
D
A B C
E
3.
2.
1.
Fig. 10
ASafety pressure limiter,
optionally with cap valve
BPressure regulator or pressure transducer,
optionally with cap valve
CPressure gauge with test valve
DFitting assembly
EWater level indicator
Installation instructions for "fittings"
Fitting the control valves (cont.)
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Temperature controller and cover panels
C
AB
2.
3.
1.
Fig. 11
ATemperature controller or poss. cover panel
BCover panel
Fit the large cover panel only if no air vent valve
(accessories) is connected to the side of the boiler.
CConnect the air vent valve either to the female
connection on top of the boiler or next to the water
level indicator. Cap any female connection that is
not used.
Fitting the control valves (cont.)
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Note
Install the electrodes for controlling and limiting the
water level in accordance with the electrode installa-
tion instructions.
Match or adjust the electrodes to the switching points
listed in the table.
Only install one electrode for limiting the water level in
each connector.
However, water level control and water level limitation
can be combined.
Ensure the electrodes of multi boiler systems are not
interchanged.
Multiple level electrode for operating pressure up to 0.5 bar (50 kPa)
2.
1.
Fig. 12
Note
See the following diagram for trimming the electrodes.
Installing electrodes (accessories)
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4321
c
a
b
NW
50
2.
1.
Fig. 13
NW Minimum water level
1. Trim the electrode rods to the stated lengths. 2. Strip the electrodes after trimming them to size.
Steam output t/h 0.26 0.44 0.7
Reference electrode to low water level NW Dim. a mm 520 565 595
Pump ON Dim. b mm 470 515 545
Pump OFF Dim. c mm 440 485 515
Note
Do not bend the electrode rods when trimming them.
Installing electrodes (accessories) (cont.)
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Combined level electrode for operating pressure up to 1.0 bar (0.1 MPa)
Water level controller
2.
1.
Fig. 14
Note
See the following diagram for trimming the electrodes.
NW
A
A
A
B
15
A
B
C
1.
2.
3.
d
abc
Fig. 15
NW Minimum water level
1. Trim the electrode rods to the stated lengths.
2. Strip the electrodes after trimming them to size.
3. Secure test area extension A on each of the
external electrode rods.
4. Push test area extension B onto the central elec-
trode rod and secure with the grub screw.
Installing electrodes (accessories) (cont.)
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5. Push locking washer C onto the central electrode
rod.
Steam output t/h 0.26 0.44 0.7
Reference electrode to low water level NW Dim. a mm 520 565 595
Pump ON Dim. b mm 470 515 545
Pump OFF Dim. c mm 440 485 515
Maximum water level Dim. d mm 375 420 450
Note
During trimming, prevent the electrode rods being
bent.
Water level limiter
2.
1.
Fig. 16
Note
See the following diagram for trimming the electrode.
Installing electrodes (accessories) (cont.)
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