Viessmann VITOPLEX 100?LS User manual

Please keep safe
VITOPLEX 100−LS
Installation 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
5592 837 GB4/2007

2
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety regulations
Installation, initial start−up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Observe all current safety
regulations as defined by DIN, EN,
DVGW, TRGI, TRF and VDE or locally
applicable standards.
See also the safety instructions sheet
in the Vitotec technical documentation
folder.
Before working on the equipment/
heating system, isolate the 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
the main gas shut−off valve and
safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations to
TRGI or TRF and all local regulations.
Please observe all commissioning
work specified for gas systems.
¨Safety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
5592 837 GB

3
Index
Page
Safety instructions2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler adjustment and positioning5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water and steam side connections6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue gas connections7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of thermal insulation
Boiler body insulation 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front rails and front insulation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear rails and rear insulation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side and rear panels 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front panels and covers 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of control fittings
Water level indicator and fitting assembly 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and covers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple level electrode for operating pressure up to 0.5bar 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagram for operating pressure up to 0.5bar 17. . . . . . . . . . . .
Level electrode combination for operating pressure up to 1.0bar 18. . . . . . . . . . . . . . . . . . .
T.D.S. valve (manual) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Desalination plant (automatic) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagram for operating pressure up to 1.0bar 26. . . . . . . . . . . .
Safety connection and checking for leaks30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner installation31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion chamber sight glass installation31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner adjustment32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important notes on commissioning32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5592 837 GB

4
Clearances
ABoiler
BBurner
CSound absorbing
boiler support
Dimensions in brackets are minimum clearances
Steam output kg/h 260 435 700
a*1 mm 1200 1300 1400
bmm Observe the burner length
Height above the boiler*2 mm 800 800 850
Anti−vibration boiler supports
Permiss. load kg 1500 1750 3000
c(front)/ number mm/piece 375/2 500/2 750/2
c(rear)/ number mm/piece 375/2 375/2 750/2
dmm 30 30 30
e(without stress) mm 42 42 42
e(stressed) mm 37 37 37
*1Maintain this space in front of the boiler to enable the withdrawal of the turbulators
or for cleaning the hot gas flues.
*2Maintain this space above the boiler to enable the installation and removal of the
multiple level electrode.
*3Maintain this side clearance when using the desalination plant.
5592 837 GB5592 837 GB
C
(50)
(300)
500
200 (100)
400 a
b
B
B
A
500
(400) 1000
*3
C
1000
*3
1000
*3

5
Boiler adjustment and positioning
1. Insert adjustable feetDinto the
bottom rails.
Note
The adjustable feet and the sight
glass closure are included in the
combustion chamber.
2. Ensure the boiler is level. Special
foundations are not required.
Note
We recommend boiler installation
on anti−vibration boiler
supportsC(see page4).
For the anti−vibration boiler
supports, the ground should be
level to within 1mm, to ensure
even loading of the spring
elements.
Position the supports under the
boiler; for this, locate them
centrally underneath the bottom
rails.
When setting the boiler down less
than square on, a boiler support
can, temporarily, be overloaded.
This can be prevented by laying
timbers (j35mm) under the
front, centre and back of each
boiler support.
5592 837 GB
D

6
Water and steam side connections
¨Safety instruction
Only open the water and steam connections after the boiler has been
completely depressurised.
Please note
Install all pipe connections free of load and torque stresses.
Thoroughly flush out the heating system, especially before connecting the
boiler to an existing heating system.
AFem. connection for fitting assembly (with twin nipple R¾"×½") Rc"
. . . . .
with 3fem. connections for pressure gauge, regulator and limiter Rb". . . . .
BConnector for water level limiter/water level regulator DN100PN16. . . . . . . . . .
CConnector for safety connection see page30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSteam connectorfor 260kg/h: DN100PN16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam connectorfor 435 and 700kg/h: DN125PN16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVentilating nipple Rc". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FConnector for water level indicator DN20PN16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GVentilating fem. connection Rc". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FFem. connection for thermostat (standby) Rb". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KFeed water connector DN40PN16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LDrain connector DN40PN16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFem. connection for cleaning R2". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NConnector for T.D.S. valve or desalination plant DN20PN16. . . . . . . . . . . . . . . . . . . . . . . .
5592 837 GB
EDBCBA
G
F
H
F
MLK N

7
Flue gas connections
Vitoair installation
instructions
1. Connect the flue outlet with the
shortest possible run to the
chimney stack using slightly
inclined flue pipes.
Flue outlet for
260 and 435kg/h ext. ∅200mm
. . . .
700kg/h ext. ∅250mm. . . . . . . . . . . . . . . . . . . . .
2. Create a test port.
3. Seal in and thermally insulate the
flue pipe (all connections/joints
must be sound).
5592 837 GB
10 mm

8
Installation of thermal insulation
Please note
All components required for the assembly of the thermal insulation are
included in the insulation carton.
Boiler body insulation
Please note
Remove and keep safe bagDwith
the type plate. This will be required
later (see page11).
ABlack side towards the outside,
for 700kg/h: 2pieces
BSeal in the sensor well
CSecure the pipe bend with its
long side and gaskets to the
flanges
EOnly if the T.D.S. valve or
desalination plant is fitted:
Secure the extension with gasket
to the flange; for this, remove the
dummy flange
5592 837 GB
7.
2.
3.
6.
4.
1.
5.
D C B
A
E

9
Installation of thermal insulation (cont.)
Front rails and front insulation
Please note
Front wall insulating mat; cut out if
required.
Secure the cutouts with spring hooks.
Close the cutouts with the enclosed
glass fibre strip.
5592 837 GB
2.
1.

10
Installation of thermal insulation (cont.)
Rear rails and rear insulation
Please note
Close the cutouts with the enclosed
glass fibre strip.
Compare the manufacturer’s details
on the back of the boiler with the
details on the type plate.
5592 837 GB
1.
2.
5.
4.4.
3.

11
Installation of thermal insulation (cont.)
Side and rear panels
AAffix the type plate Note
Request a new type plate when
replacing the side panel with the
type plate, quoting the serial no.
5592 837 GB
3.
1.
2.
5.
4.
A

12
Installation of thermal insulation (cont.)
Front panels and covers
5592 837 GB
1.
2.
3.

13
Installation of control fittings
Note
Carry out the installation in accordance with the instructions supplied with
the individual equipment. See the connection and wiring diagrams regarding
the electrical connection.
Water level indicator and fitting assembly
APressure switch
BPressure regulator
CPressure gauge
DFitting assembly
EWater level indicator
5592 837 GB
1.
2.
3.
E
D
AB C

14
Installation of control fittings (cont.)
Thermostat and covers
AControl thermostat
BCover
Fit the large cover only, if no air vent valve (accessory) is connected to the
side of the boiler.
CConnect the ventilation either to the connection on top of the boiler or
adjacent to the water level indicator. Seal off the connection which is not
used.
5592 837 GB
3.
1.
2.
C
AB

15
Installation of control fittings (cont.)
Note
Install the electrodes for water level control and the water level limiter in
accordance with the electrode installation instructions.
Match or adjust the electrodes to the switching points listed in the table.
Upon request, the electrodes supplied by the boiler manufacturer can be
matched to the boiler at the factory.
Only install one electrode for limiting the water level into each connector.
However, water level regulation and limiter can be combined.
Ensure the electrodes of multi−boiler systems are not interchanged.
Multiple level electrode for operating pressure up to 0.5bar
*1For trimming the electrode, see page16.
5592 837 GB
1.
2.
*1

16
Installation of control fittings (cont.)
NW Lowest water level 1. Trim the electrode rods to the
stated lengths.
2. Strip the electrodes after trimming
them to size.
Steam output kg/h 260 435 700
Reference electrode to NW
Pump ON
Pump OFF
Dim. a
Dim.b
Dim.c
mm
mm
mm
520
470
440
565
515
485
595
545
515
Please note
Never bend the electrode rods whilst stripping them.
Connection and wiring diagram, see page17.
5592 837 GB
50
4321
c
a
b
NW
1.
2.

17
Installation of control fittings (cont.)
Connection and wiring diagram for operating pressure up to 0.5bar
AMains electrical connection
BBurner terminals (motor,
transformer, solenoid valve,
photo cell, etc.)
CTerminals inside the control panel
(on site)
DPressure regulator,
part no. 7222165 or 7222167
EPressure switch,
part no. 7222166
FMultiple level electrode,
part no. Z002409
GTerminals for feed water pump
andblocking signal
HThermostat (standby),
part no. 7162267
KFeed water pump
LTo the burner control unit
MReset button
NInterlocking relay
OControl fuse
PFault indicator
Q2Automatic
0OFF
1Manual
RON indicator
Connect the burner in accordance with the burner manufacturer’s instructions.
All pressure regulators and the thermostat (standby) are shown in their idle
state (cold boiler).
The water level control and the water level limiter are shown in the lowest
water level position.
5592 837 GB
NRGS
S1
K2
K1
10A
2 0 1
L3L2L1
WVU
K1
K1
K2
P
32 1
11
6
8
10
5
913
S1
K2
2A
N
Ph
K
N
O
L
E FM
R
Q
P
MN
NRGS
G
D
A
C
D E
F
B
H

18
Installation of control fittings (cont.)
Level electrode combination for operating pressure up to 1.0bar
Water level regulator
*1For trimming the electrode, see page19.
5592 837 GB
1.
2.
*1

19
Installation of control fittings (cont.)
NW Lowest water level
1. Trim the electrode rods to the
stated lengths.
2. Strip the electrodes after trimming
them to size.
3. Secure test area extensionAon
each of the external electrode
rods.
4. Push test area extensionBonto
the central electrode rod and
secure with the grub screw.
5. Push locking washerConto the
central electrode rod.
Steam output kg/h 260 435 700
Reference electrode to NW
Pump ON
Pump OFF
Maximum water level
Dim. a
Dim.b
Dim.c
Dim.d
mm
mm
mm
mm
520
470
440
375
565
515
485
420
595
545
515
450
Please note
Never bend the electrode rods whilst stripping them.
Connection and wiring diagrams, see page26.
5592 837 GB
d
a
b
c
NW
15
1.
2.
3.
A
B
C
A
A
A
B

20
Installation of control fittings (cont.)
Water level limiter
5592 837 GB
1.
2.