Viessmann VITOPLEX 100 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 3/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland), Build-
ing Regulations (Northern Ireland),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions 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
supply utility from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 701 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening 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 condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative 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 poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5692 701 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 701 GB

5
Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Parts lists............................................................................................................ 19
Water quality
Water quality requirements.................................................................................. 22
Using antifreeze in boilers.................................................................................... 25
Commissioning/service reports........................................................................ 27
Specification....................................................................................................... 28
Certificates
Declaration of conformity...................................................................................... 29
Keyword index.................................................................................................... 30
Index
Index
5692 701 GB

6
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Product information
Intended use
5692 701 GB

7
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system........................................... 9
• • 2. Shutting down the system............................................. 10
• • 3. Closing the Vitoair draught stabiliser (if installed)...... 10
• • 4. Opening the boiler door and cleaning cover............... 10
•5. Cleaning the turbulators, heating surface, flue outlet
and flue pipe.................................................................... 11
••• 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................................................ 12
• • 9. Securing the boiler door and cleaning cover............... 13
••• 10. Checking connections and sensor well for leaks on
the heating water side
••• 11. Checking the function of the safety equipment........... 13
••• 12. Checking the expansion vessel and system pressure 14
••• 13. Checking the firm seating of electrical plug-in
connections and cable grommets
••• 14. Checking the thermal insulation
• • 15. Checking the water quality............................................ 15
• • 16. Cleaning the sight glass in the boiler door.................. 17
••• 17. Checking the mixer for ease of operation and
tightness.......................................................................... 17
••• 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
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 701 GB

8
Commissioning steps
Inspection steps
Maintenance steps Page
••• 21. Checking the Vitoair draught stabiliser (if installed)... 17
• • 22. Adjusting the burner...................................................... 17
•23. Instructing the system user........................................... 18
•24. Operating and service documents................................ 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 701 GB

9
Commissioning the system
Operating and service instruc-
tions for the control unit and the
burner
01. Check that the turbulators are fully
inserted into the hot gas flues (see
page 12); open the boiler door for
this.
02. Check that the installation room
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 soft-
ened 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 instal-
led).
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 man-
ufacturer's instructions).
11. When heating the system from cold
(also when restarting after mainte-
nance and cleaning work), prevent
all heat supply to heat consumers,
to clear the dew point range as
quickly as possible.
!Please note
During boiler heat-up,
unpleasant fumes and
odours can result from out-
gassing from the thermal
insulation, the heating block
and the paint.
Vent the room during com-
missioning.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 701 GB

10
12. After the flow temperature has been
reached, switch ON the heat con-
sumers in sequence and change the
burner over to automatic mode.
!Please note
When testing the flue gas for
CO, internal gases being
expelled from the heating
block can cause higher val-
ues.
Continue to operate the
boiler until a decline can be
clearly recognised.
13. Check all gaskets and plugs, and
retighten if necessary.
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
cause personal injury.
First depressurise the boiler.
Only drain the boiler with a suc-
tion 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 suc-
tion pump when the air vent valve
is open.
Closing the Vitoair draught stabiliser (if installed)
1. Start the burner. 2. With the pre-purge running, shut
down the system. The control disc will
then be closed.
Opening the boiler door and cleaning cover
Note
On gas burners, remove the gas supply
pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

11
4x
Cleaning the turbulators, heating surface, flue outlet and flue
pipe
CBA
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

12
D
3. Remove combustion residues from
the flue and the flue outlet through the
cleaning aperture in outlet D using a
vacuum cleaner.
Inserting the turbulators
!Please note
Burner adjustments and specific
system conditions can cause the
turbulators to move forward,
which may result in them being
burnt. This can also lead to dam-
age to the thermal insulation on
the boiler door.
Before insertion, the turbulators
must be slightly bent (see
steps).
10-15°
B
A
1. Push turbulators A approx. ¼ of
their length into hot gas pipes B.
2. Bend turbulators approx. 10-15°.
3. Push the turbulators into the hot gas
flues as far as they will go. When
doing this, check the prestress.
Note
Ensure that turbulators cannot easily
be pulled out of the hot gas flues.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

13
Securing the boiler door and cleaning cover
Note
Mount the gas supply pipe on gas burn-
ers.
Danger
Escaping gas leads to a risk of
explosion.
Check all gas connections for
tightness.
4x
A
Tighten screws A crosswise
(torque 25 Nm).
Danger
Leaks can result in a risk of poi-
soning through escaping gas.
Check gaskets carefully.
Checking the function of the safety equipment
Check safety valves, water level and
pressure limiter in accordance with man-
ufacturer's details.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

14
Checking the expansion vessel and system pressure
Documentation of the expansion
vessel manufacturer
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 + supplement).
The supplement is subject to the set-
tings of the high limit safety cut-out.
For a high limit safety cut-out setting
of
■ 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 pres-
sure 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 softened water*1 until the
charge pressure 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)
*1 For water quality requirements, see page 22.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

15
Pump controlled pressure maintaining systems
!Please note
Pressure fluctuations may cause
damage to the boiler or to other
system components.
In heating systems with auto-
matic pressure maintaining sys-
tems, and in particular pump con-
trolled systems with integral dea-
eration, we recommend the
installation of an expansion ves-
sel for individual boiler protec-
tion.
This reduces the frequency and
level of pressure fluctuations.
This contributes considerably to
improved operational reliability
and longer service life of the sys-
tem components.
Boiler
output
kW up to
300
up to
500
up to
1000
Expan-
sion ves-
sel
litre 50 80 140
!Please note
The ingress of oxygen can result
in system damage as a conse-
quence of oxygen corrosion.
Ensure that only pump controlled
pressure maintaining systems
that are sealed against corrosion
and protected against oxygen
ingress into the heating water are
used.
Pump controlled pressure main-
taining systems with atmospheric
deaeration through cyclical pres-
sure release create a central
post-venting of the heating sys-
tem. However, this does not rep-
resent oxygen removal in the
sense of corrosion protection
according to directive VDI 2035
sheet 2.
Carry out all checks in accordance with
the manufacturer's instructions. Limit
pressure fluctuations to the lowest pos-
sible differential. Cyclical pressure fluc-
tuations and more significant pressure
differentials point towards a system fault.
Immediately remedy such faults, other-
wise other heating system components
may become damaged.
Checking the water quality
Observe the instructions in chapter
"Water quality requirements".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

16
Enter the volume of top-up water and the
total hardness of the feed and boiler
water into the table.
Meter read-
ing
Fill and top-
up water
Total water
volume
Total hardness pH value Date
Feedwater Boiler wa-
ter
m3m3m3°dH °dH
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

17
Cleaning the sight glass in the boiler door
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 handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-ring gaskets if the mixer is leak-
ing.
4. Snap the motorised lever into place.
Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc. The control disc must swing freely during
burner operation.
Adjusting the burner
Burner service instructions or
separate documentation from the
burner manufacturer.
Adjust the maximum oil or gas through-
put of the burner to the rated boiler heat-
ing 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
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 701 GB

18
Rated
heating
output
Pressure drop on the
hot gas side
kW Pa mbar
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 condi-
tions of the flue system. Note that the flue
system must be suitable for the low flue
gas temperatures that may occur.
If the boiler frequently cycles in standby
mode and for partial loads below 40 %
we recommend thermally insulating the
flue gas collector, installing a motorised
flue gas damper and setting the mini-
mum boiler runtime to 10 minutes.
This extends the service life and reduces
the 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 serv-
ice 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
Further details regarding the individual steps (cont.)
5692 701 GB

19
Spare parts information
Quote the part no. and serial no. (see
type plate) and the position number of
the required part (as per this parts list).
Standard parts are available from your
local supplier.
Parts
001 Boiler door
002 Bolts
003 Sight glass pack, comprising:
Pos. 004 to 008
004 Hose
005 Sight glass closure
006 Sight glass with pos. 007
007 Seal ring
008 Hose nozzle
009 Hose pack Ø 18 mm
010 Thermal insulation block
011 Thermal insulation mat
013 Packing 20 x 15 mm
014 Turbulator
015 Gasket
016 Cleaning cover
017 Packing 10 x 10 mm
018 Sensor well
200 Front panel, top
201 Back panel, top
202 Back panel, bottom
203 Side panel, back left
204 Side panel, front left and back right
205 Top panel, right
206 Top panel, left
207 Thermal insulation jacket
208 Thermal insulation mat, back
209 Vitoplex 100 logo
210 Control unit fascia
211 Edge protector
212 Side panel, front right with pos. 209
Parts not shown
300 Installation instructions
301 Service instructions
302 Thermal insulation pack
303 Spray paint, Vitosilver
304 Touch-up paint stick, Vitosilver
305 Flame tube gasket pack
Accessories
020 Brush handle
021 Extension piece
022 Turbulator extractor
Wearing part
019 Cleaning brush
AType plate, optionally left or right
BBoiler control unit, see parts list in
the service instructions of the boiler
control unit
CBurner cable, see parts list in the
service instructions of the boiler
control unit
Parts lists
(cont.)
5692 701 GB

20
011
021
019
013
009
001
008
007
005
002
006
004
010
206 205
022
020
008
200
210
B
211
Parts lists
(cont.)
5692 701 GB