Viessmann VITOPLEX 100 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1, 150 to 620 kW
Oil/gas boiler
VITOPLEX 100
5692701 GB 1/2018 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 can cause burns.
■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
5692701

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.)
5692701

4
1. Product information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Ordering parts ........................................................................................ 15
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
Water quality .......................................................................................... 23
Maintenance/service .............................................................................. 23
6. Specification ................................................................................................................ 25
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 26
8. Certificates EU Declaration of Conformity ................................................................ 27
Manufacturer's certificate ....................................................................... 28
9. Keyword index ................................................................................................................ 29
Index
Index
5692701

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.
Product information
Symbols
5692701
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 the 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 temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 11
••• 14. Checking electrical plug-in connections and cable grommets for firm seating
••• 15. Checking the thermal insulation
• • 16. Checking the water quality................................................................................................ 12
• • 17. Cleaning the sight glass in the boiler door...................................................................... 12
••• 18. Checking the mixer for ease of operation and tightness............................................... 12
••• 19. Checking the function of the return temperature raising facility (if installed)
••• 20. Checking the installation room ventilation
••• 21. Checking the flue pipe for leaks
••• 22. Checking the Vitoair draught stabiliser (if installed)...................................................... 13
• • 23. Adjusting the burner.......................................................................................................... 13
•24. Instructing the system user.............................................................................................. 13
•25. 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 ventilation air aperture in the instal-
lation room 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 the appendix; see page 23.
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.
Ventilate 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 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. Tighten the 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
The connections on the heating water side must
only be opened after the boiler has been dep-
ressurised.
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
5692701

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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. Use a vacuum cleaner to remove combustion resi-
dues from the flue and the flue outlet through
cleaning aperture D in the flue outlet.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover
5692701

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Checking the thermal insulation components on the boiler door
Inserting the 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 the 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 leaks.
Commissioning, inspection, maintenance
Checking all gaskets and packing cords on the flue gas side
5692701

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4x
A
Fig. 5
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 the safety valves, water level and pressure lim-
iter in accordance with manufacturer's instructions.
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation Note
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Securing the boiler door and cleaning cover (cont.)
5692701

11
Expansion vessel
1. Drain the system until the pressure gauge indi-
cates "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 + sup-
plement).
The supplement depends on the high limit safety
cut-out setting. The following high limit safety cut-
out settings apply
■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 a diaphragm
expansion vessel for individual boiler protection.
This reduces the frequency and level of pres-
sure fluctuations. This in turn contributes signifi-
cantly 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
litres 50 80 140
!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 guideline 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, otherwise other heating system components
may suffer damage.
Checking the temperature controller setting if a building management system
is used (DCC system)
!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.
*1 For water quality requirements, see page 20.
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
5692701

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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 on
page 23.
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 leaks.
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 tightness. Replace the O-rings
if the mixer leaks.
4. Click 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 leaks
Commissioning, inspection, maintenance
Checking electrical plug-in connections and cable grommets for firm seat-
ing
5692701

13
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 from the burner manufacturer
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
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.
Ensure a (minimum) boiler return 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 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
Checking the Vitoair draught stabiliser (if installed)
5692701

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Commissioning, inspection, maintenance
Operating and service documents (cont.)
5692701

15
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
5692701
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
5692701
Components

17
Pos. Part
001 Boiler door
002 Bolt
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 (accessories)
021 Extension piece (accessories)
022 Turbulator extractor (accessories)
200 Front panel, top
205 Top panel, right
206 Top panel, left
210 Control unit fascia
211 Edge protection
Parts lists
Parts (cont.)
5692701
Components

18
202
016
017201
018203
204
208
015
015
204
014
A
212
207
C
C
209
Fig. 8
AType plate, either right or left
CBurner cable, see parts list in the service instruc-
tions of the boiler control unit
Parts lists
Parts
5692701
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
Quantity 20 22 26 26 30 30 40 45
Parts lists
Parts (cont.)
5692701
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, guideline
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 guideline.
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 conditions:
■The total volume of fill and top-up water will not
exceed 3 times the water capacity of the heating sys-
tem 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 guideline 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 > 20 l/kW
heating output (in multi boiler systems, apply the out-
put of the smallest boiler), follow the requirements for
the next highest category of total heating output (in
accordance with the table). In the case of serious
deviations (> 50 l/kW) soften down to a total of alka-
line earths ≤ 0.02 mol/m3.
Operating information:
■During expansion or repair work, only drain the pipe-
work sections necessary.
■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 the 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 filled, not 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 heating surfaces.
■In multi boiler systems, start all boilers simultane-
ously to prevent the total amount of limescale depos-
its 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.
Observing these tips minimises the formation of lime-
scale deposits on the heating surfaces.
Water quality
Water quality requirements
5692701
Appendix