Viessmann VITOPLEX 100 User manual

Installation instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1B 780 to 2000 kW 08 to 13
Oil/gas boiler
VITOPLEX 100
5461415 GB 9/2018 Dispose after installation.

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.
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
Working on the system
■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.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
5461415

3
1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
System examples .................................................................................. 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
Thermal insulation components ............................................................. 6
■Thermal insulation pack, part 1 .......................................................... 7
■Thermal insulation pack, part 2 .......................................................... 8
3. Installation sequence Siting and levelling the boiler ................................................................. 9
Changing the boiler door opening ......................................................... 10
Combustion chamber sight glass ........................................................... 10
■Mounting the combustion chamber sight glass .................................. 10
■Closing off the sight glass aperture on burners without ventilation
connection .......................................................................................... 11
Connections on the heating water side .................................................. 13
Making the safety connection and testing for tightness ......................... 13
Fitting the thermal insulation .................................................................. 14
■Boiler body thermal insulation ............................................................ 14
■Mounting the fixing rails ...................................................................... 14
■Mounting the corner rails .................................................................... 17
Mounting the control unit ....................................................................... 17
■Control unit mounting bracket, control unit back panel and burner
cables ................................................................................................. 18
■Cable trunking .................................................................................... 20
Mounting panels .................................................................................... 20
■Front panels ........................................................................................ 21
■Back panels ........................................................................................ 21
■Boiler coding card and type plate ....................................................... 22
Connections on the flue gas side ........................................................... 22
Mounting the burner ............................................................................... 23
Pressure switch ..................................................................................... 24
■Pressure switch .................................................................................. 24
Commissioning and adjustment ............................................................. 25
Index
5461415

4
Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
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.
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.
Disposal of packaging
5461415

5
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
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
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
5461415

6
(300)
200 (100)
500 (50)
400 a
b
500 (50)
Fig. 1
Dimensions in brackets are minimum clearances.
c
e
d
Fig. 2
ABoiler
BBurner
CAnti-vibration boiler supports (accessories)
Rated heating output kW 780 950 1120 1350 1700 2000
a*1 mm 1650 2150 2400
b mm Observe the installed burner length
Anti-vibration boiler supports
Permissible load kg 3000 4668 6004
c (front) / number mm/pce 750/2 667/2 834/2
c (back) / number mm/pce 750/2 500/2 667/2
d mm 30 100 100
e (unstressed) mm 42
e (stressed) mm 37
Thermal insulation components
The thermal insulation and casing are supplied in 2
packs. The following is a list of the components in the
individual packs.
*1 This space must be left clear in front of the boiler to facilitate the extraction of turbulators and for cleaning the hot gas flues.
Clearance dimensions
5461415

7
Thermal insulation pack, part 1
3
4
qW
qE
2
1
5
qU
qT
qZ
4x
3x
2x
Fig. 3
1Front panel, bottom
2Front panel, top
3Side panel
4Side panel, top, 3 x
5Side panel, control unit
qW Thermal insulation jacket
qE Thermal insulation jacket, centre
qT Thermal insulation mat, back bottom
qZ Back panel, top
qU Back panel, bottom
Thermal insulation components (cont.)
5461415

8
Thermal insulation pack, part 2
9
wR
wE
wW
7
qZ
qR
wQ
wP
qI
8
3
qP
wT
2x
2x
2x
3x3x
6
4x
Fig. 4
3Side panel
6Corner rail
7Fixing rail, right front, left back
8Fixing rail, left front, right back
9Centre rail
qP Corner rail, front right with logo
qI Mounting bracket back panel
wP Mounting bracket
wQ Mounting bracket fascia
wW Cable trunking, lower section
wE Trunking retainer
wR Cable trunking, upper section
wT Fixings:
Wing screw, self-tapping screw, spring hook, fixing
clip
Thermal insulation components (cont.)
5461415

9
1.
Fig. 5
Level the boiler horizontally. No special foundations
are required.
Note
Adjustable feet or adjustable screws with locking nuts
can also be inserted into the holes (
7
12 mm) in the
base rails (not included in the delivered condition).
Note
We recommend installing the boiler on anti-vibration
boiler supports C (see page 6).
In order to load the spring elements evenly, floor undu-
lations should not be more prominent than 1 mm.
Arrange the boiler supports underneath the boiler.
Position the supports centrally underneath the base
rails.
When the boiler is set down, single boiler supports
may temporarily be overloaded. To aid installation,
support the boiler on 3 timbers (□ 35 mm). Position
these at the front, centre and end of each boiler sup-
port.
Siting and levelling the boiler
5461415

10
D
B
A
A
B
C
C
Fig. 6
By resetting bolts A the door can be hinged on the
right.
Danger
The heavy boiler door can cause injuries.
Secure the boiler door to prevent it from tipping
over. Wear protective clothing.
During installation observe the following:
Sealing frame B should press centrally onto boiler
door gasket D when the boiler door is closed. Align
mounting bracket C if required.
Combustion chamber sight glass
Mounting the combustion chamber sight glass
The sight glass casing with accessories is supplied
inside the combustion chamber.
Changing the boiler door opening
5461415

11
1.
2.
A
Fig. 7
2. Only for burners with ventilation connection:
Connect plastic hose A with the sight glass and
the fan part of the burner (test port for "static
burner pressure").
Closing off the sight glass aperture on burners without ventilation connection
On burners without ventilation connection for sight
glass, the sight glass aperture in the boiler door is
closed off with a plug. The sight glass only serves to
cover the aperture.
Danger
When working with high temperature insulating
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.
1
1.
2.
Fig. 8
1. Check that the plug is a precise fit. If necessary,
enlarge hole in insulation block.
Combustion chamber sight glass (cont.)
5461415

12
2. Apply adhesive all around the plug. Insert plug.
Note
Adhesive drying time: 24 hours
3.
4.
Fig. 9
Combustion chamber sight glass (cont.)
5461415

13
Note
Install all pipe connections free of load and torque
stress.
ABD C
E
Fig. 10
ABoiler return
780 and 950 kW: DN 100
1120 and 1350 kW: DN 125
1700 and 2000 kW: DN 150
BSafety connection (safety valve)
780 and 950 kW: DN 50 PN 16
1120 to 2000 kW: DN 65 PN 16
CFemale connection for boiler water temperature
sensor, high limit safety cut-out and temperature
controller
DBoiler flow
780 and 950 kW: DN 100
1120 and 1350 kW: DN 125
1700 and 2000 kW: DN 150
EDrain outlet R 1¼
Flue gas collector
The version of cleaning cover on the flue gas collector
depends on the output rating.
Making the safety connection and testing for tightness
Install the safety lines.
Permiss. operating pressure 6 bar (0.6 MPa)
Test pressure 9 bar (0.9 MPa)
Note
Equip the boiler with a safety valve that is correctly
sized and suitable for heating systems.
Install all pipe connections free of load and torque
stress.
!Please note
Unsuitable water quality can damage the boiler
body.
Only fill the boiler with water that complies with
the "Water quality requirements" (see service
instructions).
Connections on the heating water side
5461415

14
Boiler body thermal insulation
Parts required from thermal insulation pack 1
qW/qE Thermal insulation jacket
qT Thermal insulation mat, bottom back
Parts required from thermal insulation pack 2
qR Thermal insulation mat, top back
wT Spring hooks from bag of fixing parts
2.
1.
3.
A
4.
Fig. 11
ABlack side outwards
Note on step 1.
Remove thermal insulation jacket from the upper boiler
cover and connect with an overlap.
Boilers up to 1120 kW are supplied with 2 thermal
insulation jacket parts; boilers from 1350 kW with 3
thermal insulation jacket parts.
Mounting the fixing rails
Parts required from thermal insulation pack 2
3Side panel
7/8Fixing rails
9Centre rails
wT Wing screws from bag of fixing parts
Fitting the thermal insulation
5461415

15
A
C
1.
16x
B
3.
2 - 3
2.
Fig. 12
ATop rail
BBase rail
CBag with type plate
1. Remove bag C containing the type plate and keep
safe. This will be required later.
Check that the serial number on the type plate
matches the serial number stamped into the back
panel of the boiler.
2. Thread the wing nuts and washer into the top and
base rails without tightening them.
3. Hook in the fixing rails. Only tighten after aligning.
Fitting the thermal insulation (cont.)
5461415

16
a
a
1.
2. 3.
Fig. 13
Aligning the fixing rails
1. Provisionally hook the side panels into position. To
provide better alignment it may be necessary to
also hook in the corner rails (see the following
page).
2. Align the fixing rails and tighten with the wing nuts.
3. Remove the side panels again.
Fitting the thermal insulation (cont.)
5461415

17
Mounting the corner rails
Parts required from thermal insulation pack 2
6/qP Corner rails
A
2.
8x
1.
3.
Fig. 14
1. Clip 2 spring clips A into each corner rail.
2. Hook corner rails into the fixing rails. Align corner
rails vertically and horizontally.
Note
Mount the corner rail with the logo at the front left.
3. Secure the corner rails with 3 screws each.
Mounting the control unit
Parts required from thermal insulation pack 2
3Side panels
4Side panels, top
5Side panel, control unit
qI Mounting bracket back panel
Fitting the thermal insulation (cont.)
5461415

18
qO Edge protector
wP Mounting bracket
Control unit mounting bracket, control unit back panel and burner cables
1.
2.
3.
Fig. 15
Prior to mounting the side panels, route the burner
cable and the boiler water temperature sensor lead.
The side panel for the control unit can be mounted on
the right or left.
Hook side panels into the slots provided, starting at the
bottom and working upwards.
!Please note
Never allow cables/leads to come into contact
with hot components.
Secure all cables/leads with cable ties if neces-
sary.
Note
If no burner cables were supplied, provide burner
cables on site.
Route the burner cables along the side of the boiler
where the boiler door is hung.
Connections to the control unit back panel
Boiler control unit installation instructions
Mounting the control unit (cont.)
5461415

19
1.
2.
3.
B4.8 x 9.5
B4.8 x 9.5
Fig. 16
Mounting the control unit
2 screws are supplied to secure the control unit.
A
A
Fig. 17
!Please note
Damaged capillaries A result in temperature
sensor faults.
Never kink the capillary tubes.
Mounting the control unit (cont.)
5461415

20
Cable trunking
Parts required from thermal insulation pack 2
wQ Mounting bracket fascia
wW Cable trunking, lower section
wR Cable trunking, upper section
wE Trunking retainer
A
4.8
7.
3.
1.
3.
2.
6. 4x
5.
4.
Fig. 18
Note on step 5.
After the cables/leads have been connected, secure
mounting bracket fascia A to the mounting bracket.
Mounting panels
Parts required from thermal insulation pack 1
1Front panel, bottom
2Front panel, top
qZ Back panel, top
qU Back panel, bottom
Mounting the control unit (cont.)
5461415