Viessmann VITOPLEX 100 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1, 780 to 2000 kW
Oil/gas boiler
For applicability, see the last page
VITOPLEX 100
5692 667 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 667 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 667 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 667 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.................................................................................... 24
Commissioning/service reports........................................................................ 26
Specification....................................................................................................... 27
Certificates
Declaration of conformity...................................................................................... 28
Keyword index.................................................................................................... 29
Index
Index
5692 667 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 667 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. Opening the boiler door and cleaning cover............... 11
•4. Cleaning the turbulators, heating surface, flue outlet
and flue pipe.................................................................... 12
••• 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................................................ 13
• • 8. Securing the boiler door and cleaning cover............... 13
••• 9. Checking all connections on the heating water side
and the sensor well for leaks
••• 10. Checking the function of the safety equipment........... 14
••• 11. Checking the expansion vessel and system pressure 14
••• 12. Checking the firm seating of electrical plug-in
connections and cable grommets
••• 13. Checking the thermal insulation for firm seating
• • 14. Checking the water quality............................................ 16
• • 15. Cleaning the sight glass in the boiler door.................. 17
••• 16. Checking the mixer for ease of operation and
tightness.......................................................................... 17
••• 17. Checking the function of the return temperature
raising facility (if installed)
••• 18. Checking the installation room ventilation
••• 19. Checking the flue pipe for tightness
• • 20. Adjusting the burner...................................................... 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 667 GB

8
Commissioning steps
Inspection steps
Maintenance steps Page
•21. Operating and service documents................................ 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 667 GB

9
Commissioning the system
Operating and service instruc-
tions for the control unit and the
burner
01. Check that the turbulators are fully
pushed into the hot gas flues (see
page 13); for this, open the boiler
door and close the gas shut-off
valve.
02. Check that the installation room
vent 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 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 the
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,
in order 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 667 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.
Shutting down the system
1. Switch OFF the mains isolator or the
power supply, and safeguard against
unauthorised reconnection.
2. Interrupt the burner power supply.
For this, pull plugs fA and lÖ from
the burner, if installed.
3. Close the gas shut-off valve.
Danger
Heating water escaping under
pressure can cause personal
injury.
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 create negative pres-
sure inside the boiler.
Drain the boiler with a suction
pump only when the air vent
valve has been opened.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

11
Opening the boiler door and cleaning cover
Note
On gas burners, remove the gas supply
pipe.
4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

12
Cleaning the turbulators, heating surface, flue outlet and flue
pipe
1. Remove turbulators A without
applying force; for this, use the turbu-
lator extractor supplied.
2. Clean flues B and combustion
chamber C with the brush.
Remove combustion residues with a
vacuum cleaner.
3. Remove combustion residues from
the flue and the flue outlet through the
cleaning aperture in outlet D using a
vacuum cleaner.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

13
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.
Lock the turbulators in place.
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 from the hot gas flues.
Securing the boiler door and cleaning cover
Note
On gas burners, remove the gas supply
pipe.
Danger
Escaping gas leads to a risk of
explosion.
Check all gas connections for
tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

14
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 the safety valves, water level and
pressure limiter in accordance with man-
ufacturer's details.
Checking the expansion vessel and system pressure
Documentation of the expansion
vessel manufacturer
Note
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

15
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: 6 bar
(0.6 MPa)
Pump controlled pressure maintaining systems
In heating systems with automatic pres-
sure maintaining systems, and in partic-
ular pump controlled systems with inte-
gral deaeration, we recommend the
installation of an expansion vessel for
individual boiler protection.
Boiler out-
put
kW up to
1000
up to
2000
Expansion
vessel ca-
pacity
litre 140 300
This reduces the frequency and level of
pressure fluctuations. This contributes
considerably to improved operational
reliability and longer service life of the
system components. Failure to observe
these recommendations may result in
damage to the boiler or to other system
components.
Furthermore ensure that only pump con-
trolled pressure maintaining systems
which are sealed against corrosion and
protected against oxygen ingress into
the heating water are used. Otherwise
damage to the system through oxygen
corrosion can result.
*1 For water quality requirements, see page 22.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

16
Pump controlled pressure maintaining
systems with atmospheric deaeration
through cyclical pressure release create
a central post-ventilation of the heating
system. However, this does not repre-
sent oxygen removal in the sense of cor-
rosion protection according to VDI 2035
sheet 2.
!Please note
Cyclical pressure fluctuations
and more significant pressure dif-
ferentials point towards a system
fault. Such faults will result in
damage to other heating system
components.
Limit pressure fluctuations to the
lowest possible differential.
Checking the water quality
Observe the instructions in chapter
"Water quality requirements".
Enter the volume of top-up water and the
total hardness of the feed and boiler
water into the table.
Meter
reading
Fill and
top-up
water
Total
water
volume
Total hardness pH val-
ue
Water treat-
ment
Date
Feed-
water
Boiler
water
Me-
dium
Meter-
ing vol-
ume
m3m3m3
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

17
The total hardness of the feed and top-
up water must not exceed a sum of all
alkaline earths of ≤ 0.02 mol/m3.
The pH value should be between 9 and
10.5.
Cleaning the sight glass in the boiler door
Note
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.
Adjusting the burner
For burner adjustment, see the
separate burner documentation.
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
780 350 3.5
950 500 5.0
1120 300 3.0
1350 400 4.0
1700 450 4.5
2000 600 6.0
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 667 GB

18
The minimum boiler water temperature
for oil and gas operation is 75 °C. Safe-
guard the boiler return temperature (min-
imum 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.
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 667 GB

19
When ordering spare parts:
Quote the part and serial numbers (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 Door (with pos. 306)
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 7 18 mm
010 Thermal insulation block
(from 1120 kW in two parts)
011 Thermal insulation mat I
013 Package GF 25 x 15
014 Turbulator
015 Gasket
016 Cleaning cover
017 Packing
018 Sensor well
025 Gasket, safety valve
200 Front panel, bottom
201 Front and back panel, top
202 Side panel, control unit
203 Side panel
204 Back l.h. rail
205 Rail, front left and back right
206 Centre rail
207 Back panel, bottom
208 Cover panel
209 Thermal insulation jacket
210 Thermal insulation jacket, centre
(only for 1120 to 2000 kW)
211 Thermal insulation mat, back
212 Thermal insulation mat, l.h. back
213 Thermal insulation mat, r.h. back
214 Control unit mounting panel
215 Mounting bracket, back
216 Channel retainer
217 Cable channel, upper section
218 Cable channel, lower section
219 Mounting bracket, fascia
220 Rail, front right (with pos. 307)
306 Viessmann logo
307 Vitoplex 100 logo
Wearing part
019 Cleaning brush
Accessories
020 Brush handle
021 Extension piece
022 Turbulator extractor
Parts not shown
300 Thermal insulation pack
301 Spray paint, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
305 Blast tube cover pack
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 667 GB

20
018
019
200
013
009
010
015
015
204
208
208
206
025
203
203
203
205
201
014
209
021020 022
210
006
002
007
005
008
001
008
011
004
Number
kW 780 950 1120
Rated heating output
Information on position 014
52
1350 1700 2000
56 66 68 74 76
306
Parts lists
(cont.)
5692 667 GB