Viessmann Vitoplex 100 PV1 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1, 150 to 620 kW
Oil/gas boiler
For applicability, see the last page
VITOPLEX 100
5692 701 GB 10/2014 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 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.
Regulations
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■The Code of Practice of relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards,
Gas Safety (Installation & Use) Regulations the
appropriate Building Regulationeither the Building
regulations, theBuilding Regulation (Scotland), Build-
ing Regulations (Northern Ireland), the Water Fittings
Regulation or Water Bylaws in Scotland, the current
I.E.E. Wiring Regulations.
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 switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supplier and your
local heating contractor from outside the build-
ing.
■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 the installation site.
■Close all doors in the living space.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an insuffi-
cient supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in proper working
order. Apertures for supplying combustion air
must be non-closable.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure a sufficient supply of combustion air.
Safety instructions
Safety instructions
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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. 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.
Danger
Hot surfaces can cause burns.
■Before maintenance or service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
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 the
system.
Faulty components must be replaced with origi-
nal Viessmann spare parts.
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 the warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 701 GB

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1. Product information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Ordering parts ........................................................................................ 14
Parts ...................................................................................................... 16
Parts ...................................................................................................... 18
4. Water quality Water quality requirements .................................................................... 20
■Prevention of damage due to scaling ................................................. 20
■Prevention of damage due to corrosion on the water side ................. 21
Using antifreeze in boilers ..................................................................... 21
5. Commissioning/service
reports
.................................................................................................................. 23
6. Specification .................................................................................................................. 24
7. Certificates Declaration of conformity ....................................................................... 25
8. Keyword index .................................................................................................................. 26
Index
Index
5692 701 GB

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Symbol Meaning
Reference to other document containing
further information
Additional information, not safety relevant
1.
Step:
The numbering corresponds to the se-
quence of work.
The work sequences for commissioning, inspection
and maintenance are summarised in the chapter
"Commissioning, inspection and maintenance "and are
marked as follows:
Symbol Meaning
Work sequences required during commis-
sioning
Not required during commissioning
Work sequences required during inspec-
tion
Not required during inspection
Work sequences required during mainte-
nance
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.
Product information
Symbols
5692 701 GB
Information

6
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 7
• • 2. Shutting down the system................................................................................................. 7
• • 3. Closing the Vitoair draught stabiliser (if installed)......................................................... 7
• • 4. Opening the boiler door and cleaning cover................................................................... 8
•5. Cleaning the turbulators, heating surface, flue outlet and flue pipe............................. 8
••• 6. Checking all gaskets and packing cords on the flue gas side
••• 7. Checking the thermal insulation components on the boiler door
•8. Inserting turbulators.......................................................................................................... 9
• • 9. Securing the boiler door and cleaning cover.................................................................. 9
••• 10. Checking connections and sensor well on the heating water side for tightness
••• 11. Checking the function of the safety equipment.............................................................. 10
••• 12. Checking the expansion vessel and system pressure................................................... 10
••• 13. Checking the firm seating of electrical plug connections and cable grommets
••• 14. Checking the thermal insulation
• • 15. Checking the water quality................................................................................................ 11
• • 16. Cleaning the sight glass in the boiler door...................................................................... 12
••• 17. Checking the mixer for ease of operation and tightness............................................... 12
••• 18. Checking the function of the return temperature raising facility (if installed)
••• 19. Checking the installation room ventilation
••• 20. Checking the flue pipe for tightness
••• 21. Checking the Vitoair draught stabiliser (if installed)...................................................... 12
• • 22. Adjusting the burner.......................................................................................................... 12
•23. Instructing the system user.............................................................................................. 13
•24. Operating and service documents................................................................................... 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating and service instructions for the control
unit and the burner
01. Check that the turbulators are fully inserted into
the hot gas flues (see page 9); open the boiler
door for this.
02. Check that the installation room supply air vent is
open.
03. Fill the heating system with water and vent the
system.
Permissible operating pressure: 5 bar (0.5 MPa)
!Please note
Scaling and boiler damage may result if the
system is not operated with fully softened
heating water.
Operate boilers only with softened water.
Observe the instructions in chapter "Water
quality requirements".
04. Enter the amount of fill water and water hardness
into the table in chapter "Checking the water qual-
ity".
05. Check the system pressure.
06. Check the oil level or the gas supply pressure.
07. Open the flue gas damper (if installed).
08. Check that the cleaning aperture on the flue outlet
is closed.
09. Open the shut-off valves in the oil or gas line.
10. Switch ON the mains isolator, the switch for the
heating circuit pump and the burner ON/OFF
switch, in that order. Observe the burner manufac-
turer’s operating instructions.
11. The dew point range must be cleared as quickly
as possible. To do so, prevent any heat supply to
the consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
!Please note
During boiler heat-up, unpleasant fumes
and odours can result from outgassing from
the thermal insulation, the thermal block and
the paint.
Vent the room during commissioning.
12. Once the flow temperature has been reached,
successively switch on the heat consumers.
Switch the burner over to automatic mode.
!Please note
When testing the flue gas for CO, internal
gases being expelled from the thermal block
can result in higher values.
Continue to operate the boiler until a decline
can be clearly recognised.
13. Check all gaskets and plugs, and retighten if nec-
essary.
14. Check the boiler door and cleaning cover after
approx. 50 hours run and retighten all screws.
Danger
Opening the connections on the heating water
side whilst the boiler is under pressure can
result in injuries.
First depressurise the boiler.
Only drain the boiler with a suction pump when
the air vent valve is open.
Shutting down the system
Danger
Only open the connections on the heating water
side after the boiler has been depressurised.
Only drain the boiler with a suction pump when
the air vent valve is open.
Closing the Vitoair draught stabiliser (if installed)
1. Start the burner. 2. When pre-purge is active, switch off the system; the
control disc is then closed.
Commissioning, inspection, maintenance
Commissioning the system
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Note
On gas burners, disconnect the gas supply pipe.
4x
Fig. 1
Cleaning the turbulators, heating surface, flue outlet and flue pipe
CBA
Fig. 2
1. Remove turbulators A without applying force.
2. Clean flues B and combustion chamber C with
the brush.
Remove combustion residues with a vacuum
cleaner.
D
Fig. 3
3. Remove combustion residues from the flue and the
flue outlet through the cleaning aperture in flue out-
let D using a vacuum cleaner.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover
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Checking the thermal insulation components on the boiler door
Inserting turbulators
!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).
10-15°
B
A
Fig. 4
1. Push turbulators A approx. ¼ of their length into
hot gas flues B.
2. Bend turbulators approx. 10 to 15°.
3. Push the turbulators into the hot gas flues as far as
they will go. When doing this, check the pre-stress-
ing.
Note
Ensure that turbulators cannot easily be pulled out
of the hot gas flues.
Securing the boiler door and cleaning cover
Note
On gas burners, mount the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
4x
A
Fig. 5
Commissioning, inspection, maintenance
Checking all gaskets and packing cords on the flue gas side
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Tighten screws A crosswise (torque 25 Nm).
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
Checking connections and sensor well on the heating water side for tight-
ness
Checking the function of the safety equipment
Check safety valves, water level and pressure limiter in
accordance with manufacturer's details.
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation Note
Carry out this test on a cold system.
Expansion vessel
1. Drain the system until the pressure gauge indicates
"0" or close the cap valve on the expansion vessel
and reduce the pressure in the expansion vessel.
Note
The pre-charge pressure of the expansion vessel
(p0) is made up of the static system pressure (pSt)
(= static head) and a supplement (p0 = pSt + supple-
ment).
The supplement depends on the high limit safety
cut-out setting. The following applies for the respec-
tive high limit safety cut-out settings
■100 °C: 0.2 bar (0.02 MPa)
■110 °C: 0.7 bar (0.07 MPa).
2. If the pre-charge pressure of the expansion vessel
is lower than the static system pressure, top up with
nitrogen until the pre-charge pressure is 0.1 to
0.2 bar (0.01 to 0.02 MPa) higher.
The static pressure corresponds to the static head.
3. Top up with softened water*1 until the charge pres-
sure of the cooled system is 0.1 to 0.2 bar (0.01 to
0.02 MPa) higher than the pre-charge pressure of
the expansion vessel.
Permiss. operating pressure: 5 bar (0.5 MPa)
Pump controlled pressure maintaining systems
!Please note
Pressure fluctuations may cause damage to the
boiler or to other system components.
In heating systems with automatic pressure
maintaining systems, and in particular pump-
controlled systems with integral deaeration, we
recommend the installation of an expansion ves-
sel for each boiler as individual boiler protection.
This reduces the frequency and level of pres-
sure fluctuations. This contributes considerably
to improved operational reliability and a longer
service life of the system components.
Boiler out-
put
kW up to
300
up to
500
up to
1000
Expansion
vessel
litre 50 80 140
*1 For water quality requirements, see page 20.
Commissioning, inspection, maintenance
Securing the boiler door and cleaning cover (cont.)
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!Please note
The ingress of oxygen can result in system dam-
age as a consequence of oxygen corrosion.
Only use pump controlled pressure maintaining
systems that are sealed against corrosion. The
pressure maintaining systems must be protected
against oxygen ingress into the heating water.
Pump controlled pressure maintaining systems
with atmospheric deaeration through cyclical
pressure release bring about central post-venti-
lation of the heating system. They do not pro-
vide oxygen removal in the sense of corrosion
protection as described in Directive VDI 2035
Part 2.
Carry out all checks in accordance with the manufac-
turer's instructions. Limit pressure fluctuations to the
lowest possible differential. Cyclical pressure fluctua-
tions and more significant pressure differentials point
towards a system fault. Immediately remedy such
faults or other heating system components may be
damaged.
Checking the firm seating of electrical plug connections and cable grom-
mets
Checking the thermal insulation
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.
Meter reading Fill and top-up water Total water volume Total hardness pH value Date
Feedwater Boiler water
m3m3m3°dH °dH
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
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The total hardness of the feed and top-up water must
not exceed 0.11 °dH (total value of alkaline earths
≤ 0.02 mol/m3).
The pH value should be between 9 and 10.5.
Cleaning the sight glass in the boiler door
Fig. 6
Check the gaskets and hose connection for tightness.
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the mixer handle.
2. Check the mixer for ease of operation.
3. Check the mixer for tightness. Replace the O-ring
gaskets if the mixer is leaking.
4. Snap the motorised lever into place.
Checking the function of the return temperature raising facility (if
installed)
Checking the installation room ventilation
Checking the flue pipe for tightness
Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc. The control disc must swing freely during burner oper-
ation.
Adjusting the burner
Burner service instructions or separate docu-
mentation by the burner manufacturer
Adjust the maximum oil or gas throughput of the
burner to the rated boiler heating output.
Commissioning, inspection, maintenance
Checking the water quality (cont.)
5692 701 GB

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Rated heating
output
Pressure drop on the hot gas
side
kW Pa mbar
150 60 0.6
200 120 1.2
250 130 1.3
310 230 2.3
400 250 2.5
410 250 2.5
500 230 2.3
620 310 3.1
The minimum boiler water temperature for oil and gas
operation is 75 °C.
Safeguard the boiler return temperature (minimum
temperature) of 65 °C.
Set the minimum heating output for the base load
stage according to the conditions of the flue system.
Note that the flue system must be suitable for the low
flue gas temperatures that may occur.
In the event of frequent cycling in standby mode and
for partial loads below 40 %, we recommend the fol-
lowing:
■Insulate the flue gas collector
■Install a motorised flue gas damper
■Set the minimum boiler runtime to 10 min
This extends the service life and reduces running
costs.
Instructing the system user
The installer should instruct the user in the operation of
the system.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand system users their section for safekeeping.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instructions
in the folder and hand this over to the system user.
The installation instructions are no longer required
after the installation is complete and therefore do
not need to be retained.
Commissioning, inspection, maintenance
Adjusting the burner (cont.)
5692 701 GB

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The following details are required when ordering parts:
■Serial no. (see type plate)
■Position number of the part (from this parts list)
Pos. Part not shown
300 Installation instructions
301 Service instructions
302 Thermal insulation, small parts
303 Touch-up spray paint, Vitosilver
304 Touch-up paint stick, Vitosilver
305 Flame tube gasket
Parts lists
Ordering parts
5692 701 GB
Components

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Parts lists
Ordering parts
5692 701 GB
Components

16
011
021
019
013
009
001
008
007
005
002
006
004
010
206 205
022
020
008
200
210
B
211
Fig. 7
BBoiler control unit, see parts list in the service
instructions of the boiler control unit
Parts lists
Parts
5692 701 GB
Components

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Pos. Part
001 Boiler door
002 Studs
003 Sight glass set, comprising: pos. 004 to 008
004 Hose
005 Sight glass closure
006 Sight glass with pos. 007
007 Seal ring
008 Hose nozzle
009 Gasket Ø 18 mm
010 Thermal insulation block
011 Thermal insulation mat
013 Gasket 20 x 15 mm
019 Cleaning brush (wearing part)
020 Brush handle (accessory)
021 Extension piece (accessory)
022 Turbulator extractor (accessory)
200 Front panel, top
205 Top panel, right
206 Top panel, left
210 Control unit fascia
211 Edge protector
Parts lists
Parts (cont.)
5692 701 GB
Components

18
202
016
017201
018203
204
208
015
015
204
014
A
212
207
C
C
209
Fig. 8
AType plate, optionally left or right
CBurner cable, see parts list in the service instruc-
tions of the boiler control unit
Parts lists
Parts
5692 701 GB
Components

19
Pos. Part
014 Turbulator
015 Gasket
016 Cleaning cover
017 Gasket 10 x 10 mm
018 Sensor well
201 Back panel, top
202 Back panel, bottom
203 Side panel, back left
204 Side panel, front left and back right
207 Thermal insulation jacket
208 Thermal insulation mat, back
209 Vitoplex 100 logo
212 Side panel, front right with pos. 209
Information on pos. 014
Rated heating output kW 150 200 250 310 400 410 500 620
Number 20 22 26 26 30 30 40 45
Parts lists
Parts (cont.)
5692 701 GB
Components

20
Note
Observing the following requirements is necessary to
safeguard your warranty rights.
The warranty excludes damage due to corrosion and
scaling.
Prevention of damage due to scaling
Prevent excessive scale build-up (calcium carbonate)
on the heating surfaces. For heating systems with
operating temperatures up to 100 °C, Directive
VDI 2035 Part 1 "Prevention of damage in water heat-
ing installations - Scale formation in domestic hot
water supply installations and water heating installa-
tions" applies together with the following standard val-
ues. See also the explanations in the original text of
the Directive.
Total heating output
kW
Total alkaline earths
mol/m3
Total hardness
°dH
> 50 to ≤ 200 ≤ 2.0 ≤ 11.2
> 200 to ≤ 600 ≤ 1.5 ≤ 8.4
> 600 < 0.02 < 0.11
The standard values assume the following:
■The total volume of fill and top-up water will not
exceed three times the water content of the heating
system during its service life.
■The specific system volume is less than 20 l/kW
heating output. In multi boiler systems, apply the out-
put of the smallest boiler.
■All measures to prevent corrosion on the water side
in accordance with Directive VDI 2035 Part 2 have
been implemented.
Soften the fill and top-up water in heating systems
operating under the following conditions:
■The total of alkaline earths in the fill and top-up water
exceeds the standard value.
■Higher fill and top-up water volumes are expected.
■The specific system volume is greater than 20 l/kW
heating output. In multi boiler systems, apply the out-
put of the smallest boiler.
■In systems > 50 kW, install a water meter to capture
the amount of fill and top-up water. Enter the volume
of fill water and the water hardness into the boiler
maintenance checklists.
■For systems with a specific system volume in excess
of 20 l/kW heating output (in multi boiler systems
apply the output of the smallest boiler), apply the
requirements of the next higher category of total out-
put (in accordance with the table). In the case of seri-
ous deviations (> 50 l/kW) soften down to a total of
alkaline earths ≤ 0.02 mol/m3.
Operating information:
■During expansion or repair work, only drain the nec-
essary pipework sections.
■Check, clean and activate filters, dirt traps and other
blow-down or separating facilities in the heating
water circuit more frequently after commissioning or
in case of new installations, later on subject to the
water treatment applied (e.g. water softening).
■No further steps are required during commissioning
if you fill the heating system with fully softened
water.
If the heating system is not filled with fully soft-
ened water, but with water that meets the require-
ments in the above table, also observe the follow-
ing during commissioning:
■Commission the system step by step, starting with
the lowest boiler output and a high heating water
flow rate. This prevents localised concentration of
limescale deposits on the boiler heating surfaces.
■In multi boiler systems, start all boilers simultane-
ously to prevent the entire limescale deposit settling
in the heat exchanger of just one boiler.
■Where water treatment is required, treat even the
first fill of the heating system prior to commissioning.
This also applies to any subsequent filling, e.g. when
adding top-up water or after a repair, or for any sys-
tem expansion.
The build-up of limescale deposits on the heating sur-
faces will be minimised if these instructions are
observed.
Water quality
Water quality requirements
5692 701 GB
Appendix