Viessmann Vitoplex 100 PV1 User manual

Installation instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1, 150 to 620 kW
Oil/gas boiler
VITOPLEX 100
5592 753 GB 10/2014 Dispose after installation.

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.
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 local standards].
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Working on the system
■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.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
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1. Information Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Clearance dimensions ........................................................................... 4
2. Installation sequence Siting and levelling the boiler ................................................................. 6
Changing the boiler door opening ......................................................... 6
Connections on the heating water side .................................................. 6
Making the safety connection and testing for tightness ......................... 7
Making connections on the flue gas side ............................................... 8
Fitting the thermal insulation .................................................................. 8
■Boiler body thermal insulation ............................................................ 8
■Rear thermal insulation ....................................................................... 9
■Side panels and burner cables ........................................................... 10
■Front panel ......................................................................................... 11
■Rear panels ........................................................................................ 11
■Preparing for the control unit installation ............................................ 12
■Routing cables .................................................................................... 12
■Top panels and type plate ................................................................... 13
■Control unit fascia ............................................................................... 14
Mounting the burner ............................................................................... 14
Mounting the combustion chamber sight glass ...................................... 14
Commissioning and adjustment ............................................................. 14
3. Specification
Index
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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.
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.
Clearance dimensions
A
(300)
200 (100)
500 (50)
400 a
b
500 (50)
B
C
Fig. 1
ABoiler
BBurner
CAnti-vibration boiler supports (accessories)
Dimensions in brackets are minimum clearances.
Symbols
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Rated heating output kW 150 200 250 310 400 410 500 620 500
a*1 mm 1100 1250 1500
bmm Observe the installed burner length.
C
c
d
e
Fig. 2
CAnti-vibration boiler support (accessory)
Rated heating output kW 150 200 250 310 400 410 500 620
Anti-vibration boiler supports
Permissible load kg 1500 2700 3336
c (front) / number mm/pce 375/2 334/2 500/2
c (back) / number mm/pce 375/2 334/2 334/2
d mm 30 100 100
e (unstressed) mm 42
e (stressed) mm 37
*1 Maintain this space in front of the boiler to enable the removal of the turbulators or for cleaning the hot gas flues.
Clearance dimensions (cont.)
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1.
Fig. 3
Level the boiler horizontally. No special foundations
are required.
Note
We recommend siting the boiler on anti-vibration
boiler supports C (see chapter "Clearance dimen-
sions").
Anti-vibration boiler supports
Floor undulations must not be greater than 1 mm to
ensure that the spring elements are loaded evenly.
Position the boiler supports underneath the boiler by
placing them centrally under the base rails.
When setting the boiler down less than square on, a
boiler support can temporarily be overloaded. To aid
installation, support the boiler on 3 x timbers
(□ 35 mm).
Changing the boiler door opening
A
A
B
C
C
D
B
Fig. 4
Note
The boiler door is hung on the opposite side by moving
bolt A to the r.h. side. Sealing frame B should press
centrally onto boiler door gasket D when the boiler
door is closed. If necessary, align mounting bracket
C.
Connections on the heating water side
Danger
Opening the connections on the heating water
side whilst the boiler is under pressure can
result in injuries.
First depressurise the boiler.
Note
Install all pipe connections free of load and torque
stress.
Siting and levelling the boiler
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E
ABCD
Fig. 5
ABoiler return
for 150 to 310 kW: DN 65
for 400 to 620 kW: DN 100
BSafety connection (safety valve), see page 7
CBoiler flow
for 150 to 310 kW: DN 65
for 400 to 620 kW: DN 100
DFemale connection for boiler water temperature
sensor, high limit safety cut-out and temperature
controller
EDrain, R 1¼
Making the safety connection and testing for tightness
Install the safety lines.
Safety connection
150 to 310 kW R 1¼
400 to 620 kW R 1½
Permiss. operating pressure 5 bar (0.5 MPa)
Test pressure 6.5 bar (0.65 MPa)
Low water indicator
According to EN 12828, a low water indicator can be
omitted for Vitoplex 100 boilers up to 300 kW (except
in attic heating centres), as the standard boiler control
unit prevents impermissible heating.
If required, install a low water indicator or a minimum
pressure limiter into the pipework.
Note
Equip the boilers with a safety valve that is type-tested
according to EN 4126. The valve must be marked in
accordance with the system version.
Install all pipe connections free of load and torque
stress.
!Please note
Unsuitable water quality can damage the boiler
body.
Only fill the boiler with water that complies with
the "Water quality requirements" (see service
instructions).
Connections on the heating water side (cont.)
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Ø D Ø 10
2-3 x Ø D
Fig. 6
Vitoair installation instructions
1. Connect the flue outlet with the shortest possible
run to the chimney and maintain a slight incline.
External Ø, flue outlet:
150 and 200 kW: 178 mm
250 and 310 kW: 198 mm
400 to 620 kW: 248 mm
2. Create a test port.
3. Seal in and insulate the flue pipe. Joints must be
gas-tight.
Fitting the thermal insulation
Note
All components required for fitting the thermal insula-
tion can be found in the thermal insulation box.
Boiler body thermal insulation
B A
4.
2.
3.
1.
Fig. 7
ABlack side outwards
Making connections on the flue gas side
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Note
Remove bag B containing the type plate and keep
safe. This will be required later.
Rear thermal insulation
2.
1.
Fig. 8
Note
Check that the serial number on the type plate
matches the serial number stamped into the back
panel of the boiler.
Fitting the thermal insulation (cont.)
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Side panels and burner cables
4x
3.9 x 9.5
4x
4.
5.
1.
2.
A
3.
B
lÖ
fA
Fig. 9
ASide panel, front right
BVitoplex 100 logo
Note
Provide burner cables on site if they are not supplied.
The inclusion of burner cables in the standard delivery
depends on which control unit is being supplied.
Note
Route the burner cables fA and lÖ along the side of
the boiler where the boiler door hinges are located.
Fitting the thermal insulation (cont.)
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Front panel
2
3,9 x 9,5
2.
3,9 x 9,5
3.
1.
Fig. 10
Rear panels
3,9 x 9,5
3,9 x 9,5
2.
1.
Fig. 11
Fitting the thermal insulation (cont.)
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Preparing for the control unit installation
Connections to the back of the control unit: See
boiler control unit installation instructions.
Note
■Boiler water temperature sensor § is supplied in the
control unit pack.
■Boiler coding card A is included in the product pack
(not used for thermostat control).
■Insert the probe and the boiler water temperature
sensor as far as they will go into the sensor wells.
■Power supply plug fÖ is supplied with the control
unit.
!Please note
Damaged capillary tubes will result in faulty sen-
sor function.
Never kink the capillary tubes.
6 x 12
2.
1.
Fig. 12
Note
Screws (6 x 12) can be found with the control unit fas-
cia (packed separately with the thermal insulation).
Routing cables
A
1.
1.
2.
2.
Fig. 13
ABoiler coding card
Note
Bundle and secure the LV cables.
Route 230 V cables and LV leads separately.
Fitting the thermal insulation (cont.)
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Top panels and type plate
A
B
3,9 x 9,5
4.
2.
3.
1.
5.
3,9 x 9,5
3,9 x 30
Fig. 14
ABoiler type plate
Fitting the thermal insulation (cont.)
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Control unit fascia
1.
Fig. 15
Mounting the burner
Separate burner documentation
The burner fixing hole circle, burner fixing holes and
flame tube aperture meet the requirements of
EN 303-1.
The burner may be mounted directly on the hinged
boiler door. If the burner dimensions deviate from
those stated in EN 303-1, fit the blank plate available
as an accessory. For this, drill fixing holes to suit the
burner in question into the burner plate.
■Cut out the thermal insulation mat in the boiler door
to suit the flame tube diameter.
Note
The flame tube must protrude from the thermal insu-
lation of the boiler door.
To safeguard perfect operation, maintain the
required minimum flame tube length.
■After mounting the burner, seal the annular gap
between the flame tube and the thermal insulation
block with the flame tube gasket supplied.
Note
Failure to observe this can result in boiler door dam-
age due to excessive temperatures.
Mounting the combustion chamber sight glass
Connect the sight glass (sight glass closure supplied
inside the combustion chamber) with the fan part of the
burner (test port for "static burner pressure") using the
plastic hose supplied.
Commissioning and adjustment
Service instructions for boiler and boiler control
unit and separate burner documentation
Fitting the thermal insulation (cont.)
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Rated heating output kW 150 200 250 310 400 410 500 620
Flue gas parameters*2
Temperature at boiler water
temp. 80 °C
■at rated heating output °C 215
■at partial load (60 %) °C 155
Product ID CE-0085BP0365
Efficiency η at
■100 % of the rated heating
output (80/65 °C)
% 90.8 91.0 90.9 91.0 90.9 90.9 91.0 91.1
■30 % of the rated heating
output (80/65 °C)
% 94.5 94.9 94.7 95.0 94.7 94.7 95.0 95.2
*2 Values for sizing the flue system to EN 13384 relative to 13 % CO2 for fuel oil EL and 10 % CO2 for natural gas.
Specification
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Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5592 753 GB Subject to technical modifications.