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

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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
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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
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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
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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

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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

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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