Viessmann VITOPLEX 100?LS Quick guide

VITOPLEX 100−LS
Installation and
service instructions
for heating engineers
Vitoplex100−LS
TypeSXD, 0.26 to 0.7 t/h
Oil/gas fired boiler
Steam generator up to 1bar operating pressure
5692729 GB4/2007 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
If you smell gas
HDo not smoke! Do not use naked
flames or cause sparks (e.g. by
switching lights or electrical
appliances ON or OFF)
HOpen windows and doors
HClose gas shut−off valve
HNotify your heating engineer/
installation contractor from outside
the building
HObserve the safety regulations of
your gas supplier (see gas meter)
and of your local heating
contractor (see commissioning/
training report).
In an emergency
HImmediately switch OFF emergency
stop switch (outside boiler room)
(except if you smell gas).
HClose the shut−off valves of the
main fuel lines.
HFor fire, use an appropriate fire
extinguisher.
Work on the equipment
Installation, initial start−up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Before working on equipment/ heating
system, isolate its mains electrical
supply (e.g. by removing a separate
mains fuse or by means of a mains
electrical isolator) and safeguard
against unauthorised reconnection.
When using gas as fuel, also close
main gas shut−off valve and safeguard
against unauthorised reopening.
Installation of additional components
Installation of additional components
which have not been tested together
with the boiler can adversely affect the
boiler function.
Our warranty does not cover and we
accept no liability for damage caused
by the installation of such components.
Boiler room conditions
HDo not use where air is polluted
with halogenated hydrocarbons
(e.g. as in aerosols, paints,
solvents and cleaning agents)
HPrevent very dusty conditions
HAvoid rooms with permanently
high levels of humidity
HRoom should be frost protected
HEnsure good ventilation, and never
close any vents.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work for gas installations specified
according to TRGI or TRF, or local
regulations.
Repair work
It is not permitted to carry out
repairs on parts that fulfil a safety
function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start−up
Initial start−up must be carried out by
the system installer or a designated
commissioning engineer. All actual
values should be recorded in a
commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨Safety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes information
which must be observed to
prevent material losses.
5692729 GB

3
Contents
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notice of completion 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Steps 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnostics 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Water quality requirements according to TRD70126
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specification 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformity 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer’s certificate 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notice of completion
Within four weeks of the initial
commissioning of the combustion
equipment, the operator must notify
the local chimney sweep accordingly
[in Germany; check local regulations].
5692729 GB

4
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C M 1. Adjusting pressure regulator and pressure limiter 6. . . . .
C M 2. System start−up 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3. System shutdown 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 4. Closing the Vitoair draught stabiliser (if installed) 9. . . . .
M5. Opening the boiler door and the clean−out cover 9. . . . . . .
M6. Removing and cleaning the turbulators 10. . . . . . . . . . . . . . . . . . . . . . . . . .
M7. Cleaning heating surface, flue outlet and flue pipe 11. . . .
I M 8. Checking all seals/gaskets and packing cords
on flue gas side
M9. Checking thermal insulation of boiler door
M10. Inserting the turbulators 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M11. Securing the boiler door and clean−out cover 13. . . . . . . . . . . . . . .
M12. Checking the water chamber for deposits 14. . . . . . . . . . . . . . . . . . . . . .
M13. Cleaning the multiple level electrode 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14. Cleaning the water level indicator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M15. Checking all connections at the water and
steam sides, the sensor well and the
inspection ports for leaks after filling the boiler 16
. . . . . . . . . .
I M 16. Cleaning the sight glass in the boiler door 16. . . . . . . . . . . . . . . . . . . .
I M 17. Checking the Vitoair draught stabiliser (if installed) 17.
M18. Adjusting the burner 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 19. Checking the safety valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 20. Checking the safety and control equipment
5692729 GB

5
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance (cont.)
Commissioning steps
Inspection steps
Maintenance steps Page
M21. Checking the pressure regulator, pressure limiter
and thermostat (standby) 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M22. Checking the water quality 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 23. Checking thermal insulation
I M 24. Checking the boiler room ventilation
I M 25. Checking the flue pipe for leaks
5692729 GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps
Maintenance instructions
We recommend that your boiler system is maintained regularly by a heating
specialist to ensure fault−free, energy−conscious and environmentally safe
operation of your heating system.
Your boiler must be cleaned at regular intervals, otherwise the flue gas
temperature rises with increasing contamination, which leads to higher
energy losses.
We recommend the use of a flue gas thermometer.
Monitoring the flue gas temperature highlights incorrect burner settings and
the level of boiler contamination.
Excessive flue gas temperatures through boiler contamination or incorrect
burner setting reduces the system efficiency. Where necessary, clean the
boiler or adjust the burner settings.
Adjusting the pressure regulator and pressure limiter
1. Adjust the pressure limiter
response pressure a little higher
than that of the pressure regulator.
2. Secure the protective cap again on
the pressure limiter to prevent any
unauthorised adjustment at a later
time.
3. During commissioning, adjust the
pressure regulator to the required
operating pressure.
Do not alter this setting later.
Adjust the pressure regulator for
stage 1 a little higher and a little
lower for stage 2.
Note
Each pressure regulator is
equipped with a setting screw
each for adjusting the switching
point (e.g. 0.45bar) and for
selecting the switching differential
(e.g. 0.02bar), i.e., the pressure
regulator starts the burner at
0.43bar and switches it OFF at
0.45bar.
5692729 GB

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
According to the [German] Health & Safety at Work Act, steam boilers with a
safety pressure in excess of 0.5bar must be monitored. In accordance with
the conformity assessment diagram no.5 of the EU Pressure Equipment
Directive, these boilers must be categorised as classIII. Prior to
commissioning, this system must be tested by an authorised body (e.g. TÜV).
System start−up
Observe the information
provided by the suppliers of
burner and accessories.
1. Check that turbulators are fully
pushed into hot gas flues
(against their end stop)
(open boiler door).
2. Check that the boiler room
ventilation is unobstructed.
3. Check the function of the water
treatment system.
4. Fill the steam boiler with water
higher than the NW indicator.
Note
Only operate steam boilers with
suitable water; see also water
quality requirements on page26.
5. Check all fitted components, such
as pipework, valves, regulators,
pumps etc. for function and
leaks.
6. Check the fuel oil level or the gas
supply pressure.
7. Open the flue gas damper (where
appropriate).
8. Check whether cleaning aperture
on the flue outlet is closed.
9. Open the shut−off valves in oil
supply pipes (at the oil tank and
filter) or open the gas shut−off
valve, whichever is applicable.
10. Switch ON the mains electrical
isolator, the switch for the feed
water pump and the burner
ON/OFF switch, in that order.
Burner manufacturer’s
operating instructions
11. Start the boiler with a low output
(burner stage1 or partial load)
and slowly ramp up to the
required operating pressure.
12. Slowly open the steam valve
after the required operating
pressure has been reached.
13. Only enable the full burner load
at that point.
14. While the system heats up, check
the correct function of all control
and safety equipment.
15. Observe the pressure and
temperature test equipment.
16. Check the fittings for leaks and
tighten, if necessary.
17. Check the boiler door and
clean−out cover after approx.
50hours and retighten all
screws.
Note
We would recommend that you
operate the boiler constantly at the
required operating pressure.
The boiler may still be operated at
pressure, even if no heat demand
occurs for a longer period of time.
In systems comprising several
boilers, of which one is constantly
used as standby boiler, only change
the operation over in longer
intervals, e.g. during the annual
inspection of the total system.
5692729 GB

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
System shutdown
¨Safety instruction
Only open the water and steam
connections and the inspection ports
after the boiler has been completely
depressurised.
1. Close the shut−off valves in the oil
supply pipes (at the oil tank and
filter) or the gas shut−off valve,
whichever is applicable.
2. Switch OFF the burner and the
feed water pump. Pull the
connecting plug from the burner.
3. Isolate the system from the mains
power supply.
4. Close all valves.
Information regarding system shutdowns
If you do not require to use your
boiler system temporarily, maintain
the boiler water temperature by
means of the thermostat (standby) at
95ºC, to prevent corrosion through
ingress of oxygen into the boiler
water.
If you want to shut down your
heating system for longer periods of
time (several months), shut it down
completely.
HBefore taking the system out of use
for longer periods, we recommend
you take certain measures, e.g.
protecting the system against frost
or preserving the heating surfaces.
HThoroughly clean the surfaces on
the flue gas side to preserve the
heating surfaces. Then conserve
these surfaces with a preserving oil
mixed with graphite.
HFor the protection of the water
side, we recommend you flood the
boiler with degassed, oxygen−free
and treated water with low salt
content and added oxygen binders
(e.g. sodium sulphite).
Then close the steam shut−off
valve.
Check the concentration of the
oxygen binder at least every month
and replenish, if necessary. When
doing this, ensure that the binder is
well−mixed with water inside the
boiler.
HAnother option is that of dry
preservation, which is
recommended for shutdown
periods longer than 4weeks.
HWhen there is a risk of frost, drain
the boiler and the heating system
via the drain plug.
Open the shut−off and regulating
valves as well as the air vents.
5692729 GB

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Closing the Vitoair draught stabiliser (if installed)
1. Switch ON the burner. 2. Switch OFF the system, when
pre−purge is running; this closes
the control disc.
Opening the boiler door and the clean−out cover
Note
Remove the gas supply pipe on gas
burners.
5692729 GB
4x

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Removing and cleaning the turbulators
Remove turbulatorsAwithout
force; for this, use the turbulator
pulley, which is part of the cleaning
equipment.
5692729 GB
A

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Clean the heating surface, flue outlet and flue pipe
1. Clean fluesAand combustion
chamberBwith brushes and
remove combustion residues.
2. Remove combustion residues
from the flue pipe and the flue
outletC.
5692729 GB
BA
C

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Inserting the turbulators
¨Burner adjustments and specific system conditions can lead the
turbulators to move forward, which may result in them being burnt. The
thermal insulation on the boiler door can also be damaged by this.
1. Pull approx ¾ of the length of
turbulatorsAout of secondary
heating pipesB.
2. Bend turbulators approx. 1015º.
3. Insert the turbulators into the
secondary heating pipes. When
doing this, check the preliminary
tension.
Note
Turbulators must not be able to be
pulled from the secondary heating
pipes easily.
5692729 GB
A B

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Securing the boiler door and clean−out cover
Note
Refit the gas supply pipe on gas burners.
¨Safety instruction
Carry out a leak test on all gas supply connections.
ATighten the screws diagonally.
5692729 GB
4x
A

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the water chamber for deposits
1. Open hand hole coverA.
2. Fully drain the boiler.
3. Clean the water chamber (hose it
out) and remove deposits via the
blow−down valve and drain. In
case of harder deposits which
cannot be removed by hosing
down, carry out a chemical
cleaning process using added
descaler.
4. Clean all sealing faces on closures,
and replace gaskets, where
required. Retighten new gaskets
after commissioning and recheck
after 24hours.
5692729 GB
A

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning the multiple level electrode
1. Remove electrodeA.
2. Clean electrode tipsC.
3. Clean the sealing faces and use a
new gasketB.
4. Install the electrodes and carry out
a safety test in line with the
manufacturer’s instructions.
5. Retighten new gaskets after
commissioning.
Cleaning the water level indicator
1. Blow out the water level indicator.
2. Remove upper plugA, and clean
the water level indicator with a
brush.
5692729 GB
A
B
C
A

16
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking all connections at the water and steam sides, the
sensor well and the inspection ports for leaks after filling the
boiler
Each time inspection ports have
been opened:
1. Clean the sealing surface.
2. Replace the gasket.
3. Retighten all connections after
restarting the system.
For testing the sensor well, remove
coverA.
Cleaning the sight glass in the boiler door
Check gaskets and hose connection
for leaks.
5692729 GB
A

17
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
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 manufacturer’s
details
During adjustments, observe the
minimum output.
Set the minimum heating output for
the base load stage according to the
chimney conditions.
Checking the safety valve
Manufacturer’s details Raise the operating pressure to the
response pressure or manually vent
when 85% of the response pressure
has been reached.
Checking the pressure regulator, pressure limiter and
thermostat (standby)
Check the pressure regulator,
pressure limiter and thermostat
(standby) for function and correct
adjustment.
The control thermostat (standby)
must be adjusted to a minimum
of 95ºC.
5692729 GB

18
Troubleshooting
Diagnostics
Fault/
system characteristics
Cause Remedy
Burner does not start No voltage Switch ON the mains
electrical isolator
Safety chain activated Check all safety
equipment
Burner fault indicator
illuminates
Press the reset button at
the burner control unit
Fuel supply interrupted Open the shut−off valves
in the fuel supply line
and filter
Remedy other faults in accordance with the burner
manufacturer’s instructions
Oxygen corrosion
(water side)
Topping up with
unsuitable water
Check water treatment
system and injection
equipment in
accordance with VdTÜV
[or local] guidelines
Boiler is completely shut
down every day
Switch to standby
(95ºC) instead of a
complete shutdown
Flue gas temperature
too high
Heat transfer is reduced
by contamination on the
flue gas and water side
Clean the boiler
Rated boiler output is
exceeded
Check the rated burner
output
Turbulators missing or
incorrectly installed
Carry out maintenance
and installation in acc.
with page10 and 12
The safety valve
blows down
Blow−down pressure is
not identical with the
system pressure
Check the operating
pressure with a suitable
pressure gauge
Valve seat contaminated Clean the valve seat
Water trap pipe
(upstream of pressure
regulator) is clogged up
Clean pipes
5692729 GB

19
Troubleshooting
Diagnostics (cont.)
Fault/
system characteristics
Cause Remedy
The boiler produces wet
steam
The boiler water
alkalinity is too high
Regularly blow down
the boiler and install a
desalination system, if
required; treat water
according to EN12953.
Dewater the
downstream steam line.
The water level is set too
high
Check the boiler and feed
water daily. Check the
electrode length.
Steam knocking inside
the boiler
The feed water does not
enter via the feed water
connector
Connect the feed water
line to the correct
connector
Steam knocking inside
the condensate
container
Check valve in the feed
water line is missing or
faulty
Install or clean the check
valve (observe the flow
direction)
Faulty system
condensate drain
Identify and repair the
faulty drain
U bends buckle Reduce the steam
pressure
The water level in the
boiler is too high
The steam distributor
above the boiler is
insufficiently dewatered
Install a condensate
drain
5692729 GB

20
Troubleshooting
Diagnostics (cont.)
Fault/
system characteristics
Cause Remedy
Water level limiter
switches OFF
The shut−off valve in the
feed water line is closed
Open the shut−off valve
No feed water in the
condensate container
Check the mains water
connection
The feed water pump or
water level control is
faulty
Determine the cause for
the fault on the water
level control in
accordance with the
controller installation
instructions
Severe water level
fluctuations through
excessive alkalinity
Drain water from the
boiler and the
condensate container.
If a desalination valve is
fitted, increase the
desalination rate.
Refill with treated water.
Blow−down more
frequently. Check the
water treatment system.
5692729 GB