Viessmann VITOPLEX 100 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1B, 780 to 2000 kW 08 to 13
Oil/gas boiler
VITOPLEX 100
5461424 GB 9/2018 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.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
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.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and 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.
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
5461424

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.
Safety instructions for operating the system
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. Never 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 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 heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
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 external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform 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 inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Parts lists Ordering parts ........................................................................................ 17
Boiler body assembly ............................................................................. 18
Thermal insulation assembly ................................................................. 20
4. Water quality Water quality requirements .................................................................... 22
■Heating systems with rated operating temperatures up to 100 °C
(VDI 2035) .......................................................................................... 22
■Prevention of damage through corrosion on the water side ............... 22
Using antifreeze in boilers ..................................................................... 23
5. Commissioning/service
reports
Water quality .......................................................................................... 24
Maintenance/service .............................................................................. 24
6. Specification ................................................................................................................ 26
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 27
8. Certificates EU Declaration of Conformity ................................................................ 28
Manufacturer's certificate ....................................................................... 28
9. Keyword index ................................................................................................................ 29
Index
Index
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5
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
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.
Information
Symbols
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Information

6
Vitoplex 100, type PV1B
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 6 bar (0.6 MPa)
■Rated heating output 780 to 2000 kW
Information
Product information
5461424
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 8
• • 2. Shutting down the system................................................................................................. 8
• • 3. Opening the boiler door and cleaning cover................................................................... 9
•4. Cleaning the turbulators, heating surface, flue outlet and flue pipe............................. 10
••• 5. Checking all gaskets and packing cords on the flue gas side
••• 6. Checking the thermal insulation components on the boiler door
•7. Inserting the turbulators.................................................................................................... 10
• • 8. Securing the boiler door and cleaning cover.................................................................. 11
••• 9. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 12
••• 10. Checking all connections on the heating water side and the sensor well for leaks
••• 11. Checking the function of safety equipment..................................................................... 12
••• 12. Checking the function of the pressure switch................................................................ 12
••• 13. Checking the expansion vessel and system pressure................................................... 12
••• 14. Checking electrical plug-in connections and cable grommets for firm seating
••• 15. Checking the thermal insulation for firm seating
• • 16. Checking the water quality................................................................................................ 13
• • 17. Cleaning the sight glass in the boiler door...................................................................... 14
••• 18. Checking the mixer for ease of operation and tightness............................................... 14
••• 19. Checking the function of the return temperature raising facility (if installed)
••• 20. Checking the installation room ventilation
••• 21. Checking the flue pipe for tightness
• • 22. Adjusting the burner.......................................................................................................... 14
•23. Operating and service documents................................................................................... 15
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 10). To check, close
the gas shut-off valve and open the boiler door.
02. Check that the ventilation air aperture in the instal-
lation room is open.
03. Fill the heating system with water and vent the
system.
Permissible operating pressure: 6 bar (0.6 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 this order (observe the burner manufac-
turer's instructions).
11. The dew point range must be cleared as quickly
as possible. For this reason prevent all heat sup-
ply to consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
!Please note
During the initial boiler heat-up, unpleasant
fumes and odours can result from outgas-
sing from the thermal insulation, the thermal
insulation block and the paint.
Ventilate the room during commissioning.
12. After the flow temperature has been reached,
switch ON the heat consumers in sequence and
change the burner over to automatic mode.
!Please note
When checking CO levels in the flue gas,
internal outgassing 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.
Torque
Screws, boiler door 25 Nm
Screws, cleaning cover 7 Nm
Shutting down the system
1. Switch OFF the mains isolator or the power supply,
and safeguard against unauthorised reconnection.
2. Interrupt the power supply to the burner. For this,
pull plugs fA and lÖ from the burner, if fitted.
3. Close the gas shut-off valve.
Danger
Heating water escaping under pressure will
injure bystanders.
Only open the connections on the heating water
side after the boiler has been depressurised.
!Please note
Draining the boiler with a suction pump will cre-
ate negative pressure inside the boiler.
Only drain the boiler with a suction pump when
the air vent valve is open.
Commissioning, inspection, maintenance
Commissioning the system
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Note
On gas burners, disconnect the gas supply pipe.
4x
Fig. 1
Danger
When working with high temperature insulation
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.
Cleaning cover
The version of cleaning cover on the flue gas collector
depends on the output rating.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover
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Fig. 2
1. Remove turbulators A without applying force
using the turbulator extractor supplied.
2. Clean flues B and combustion chamber C with
the brush.
Remove combustion residues with a vacuum
cleaner.
Fig. 3
3. Use a vacuum cleaner to remove combustion resi-
dues from the flue and the flue outlet through
cleaning aperture D in the flue outlet.
Cleaning cover
The version of cleaning cover on the flue gas col-
lector depends on the output rating.
Checking all gaskets and packing cords on the flue gas side
Checking the thermal insulation components on the boiler door
Inserting the turbulators
!Please note
Some burner settings and specific system condi-
tions can cause the turbulators to move forward
and be burnt as a consequence. This can also
lead to damage to the thermal insulation on the
boiler door.
Lock the turbulators in place.
Commissioning, inspection, maintenance
Cleaning the turbulators, heating surface, flue outlet and flue pipe
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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 the turbulators cannot easily be pulled
out of the hot gas flues.
Securing the boiler door and cleaning cover
Note
On gas burners, disconnect the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
4x
A
Fig. 5
Torque
Screws A, boiler door 25 Nm
Screws, cleaning cover 7 Nm
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
Commissioning, inspection, maintenance
Inserting the turbulators (cont.)
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!Please note
Shutting down from full load can result in high
material stress and material damage to the
boiler.
If a system with a higher ranking building man-
agement system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller TR to at least 10 K below
the mechanical temperature controller TR of the
Vitotronic.
Checking all connections on the heating water side and the sensor well for
leaks
Checking the function of safety equipment
Check safety valves, water level and pressure limiter in
accordance with manufacturer's instructions.
Checking the function of the pressure switch
Installation instructions, pressure switch set
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 shows
"0". Alternatively: 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 + sup-
plement.
The supplement depends on the high limit safety
cut-out setting. The following applies:
■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: 6 bar (0.6 MPa)
*1 See chapter "Water quality requirements".
Commissioning, inspection, maintenance
Checking the temperature controller setting if a building management system
is used (DCC system)
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Pump controlled pressure maintaining systems
In heating systems with automatic pressure maintain-
ing systems also provide individual protection by instal-
ling an expansion vessel for each boiler. This applies
in particular to pump controlled systems with integral
deaeration.
Boiler output kW Up to 1000 Up to 2100
Expansion
vessel
l 140 300
The individual protection reduces the frequency and
level of pressure fluctuations. This significantly increa-
ses the operational reliability and service life of the
system components. Failure to observe these recom-
mendations may result in damage to the boiler or to
other system components.
Only use pump controlled pressure maintaining sys-
tems that are sealed to prevent corrosion. The pres-
sure maintaining systems must be protected against
oxygen ingress into the heating water. Otherwise dam-
age to the system through oxygen corrosion can result.
Pump controlled pressure maintaining systems with
atmospheric deaeration through cyclical pressure
release effect a central post-ventilation of the heating
system. They do not provide oxygen removal in the
sense of corrosion protection as described in VDI 2035
Part 2.
Note
Check the pressure maintaining system in line with the
manufacturer's instructions.
!Please note
Cyclical pressure fluctuations and more signifi-
cant pressure differentials point towards a sys-
tem fault. Such faults result in damage to other
heating system components.
Limit pressure fluctuations to the lowest possible
differential.
Checking electrical plug-in connections and cable grommets for firm seat-
ing
Checking the thermal insulation for firm seating
Checking the water quality
Observe the instructions in chapter "Water quality
requirements" on page 22.
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table on
page 24.
The total hardness of the feed and top-up water must
not exceed the sum of all alkaline earths
≤ 0.02 mol/m3.
The pH value should be between 9 and 10.5.
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
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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 han-
dle.
2. Check the mixer for ease of operation.
3. Check the mixer for leaks. In the event of a leak,
replace the O-ring.
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
Adjusting the burner
For burner adjustment, see separate burner
documentation.
Adjust the maximum oil or gas throughput of the
burner to the rated boiler heating output.
Rated heating
output
Pressure drop on the hot gas
side (fuel oil*2)
kW Pa mbar
780 350 3.5
950 450 4.5
Rated heating
output
Pressure drop on the hot gas
side (fuel oil)
kW Pa mbar
1120 590 5.9
1350 570 5.7
1700 720 7.1
2000 540 5.4
*2 Values for natural gas plus around 5 %
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door
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The minimum boiler water temperature for oil and gas
operation is 75 °C. Ensure the (minimum) boiler return
temperature of 65 °C.
Partial load operation
Set the minimum heating output for the base load
stage in accordance with the flue system. The flue sys-
tem must be suitable for the low flue gas temperatures.
In the case of frequent cycling in standby mode and for
partial loads below 40 % we recommend that you:
■Insulate the flue gas collector
■Install a motorised flue gas damper
■Set the minimum runtime of the boiler to 10 min
This extends the service life and reduces running
costs.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand the system user their section for safekeep-
ing.
■Retain the heating contractor's section.
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 is complete and therefore do
not need to be retained.
Commissioning, inspection, maintenance
Adjusting the burner (cont.)
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Commissioning, inspection, maintenance
Operating and service documents (cont.)
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17
The following details are required when ordering parts:
■Serial no. (see type plate)
■Position number of the part from this parts list
Parts not shown
Pos. Part
0001 Touch-up spray paint, Vitosilver
0002 Touch-up paint stick, Vitosilver
0003 Installation instructions
Parts lists
Ordering parts
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Components

18
0013
0010
0015
0011
0001
0012
0008
0009
0007
0006
0005
0015
0016
0004
0002
0014
00040003
Fig. 7
Parts lists
Boiler body assembly
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Components

19
Pos. Part
0001 Boiler door
0002 Bolt B 12 h11 x 120
0003 Sight glass
0004 Viessmann logo
0005 Thermal insulation mat
0006 Thermal insulation block
0007 Flame tube gasket
0008 Hose packing
0009 Packing GF 25 x 15
0010 Turbulator
0011 Turbulator extractor
0012 Gasket DN 100/125/150
0013 Gasket DN 50/65
0014 Sensor well
0015 Glass fibre-reinforced fabric tape
0016 Cleaning cover*3
0017 Cleaning brush (wearing part)
Information on pos. 0010
Rated heating output kW 780 950 1120 1350 1700 2000
Number of turbulators 48 56 66 68 76 70
*3 Version depends on output rating. For 1700/2000 kW: 2 round cleaning covers
Parts lists
Boiler body assembly (cont.)
5461424
Components

20
0011
0012
0002
0001
0018
0021
0020
0024
0022
0023
0003
0003
0004
0009
0003
0003
0005
0008
0006
0010
0007 0004
0003
0003 0009
0003
0003
0004
0012
0013
0025
0006
0008
0015
0014
0016
0007
0006
0011
0019
0019
0017
Fig. 8
Parts lists
Thermal insulation assembly
5461424
Components