Viessmann Vitoplex 200 Series Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 200
Type SX2A, 700 to 1950 kW
Oil/gas boiler
VITOPLEX 200
5692849 GB 9/2018 Please keep safe.

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.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
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
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■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.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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 func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5692849

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never 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.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692849

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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Parts lists Ordering parts ........................................................................................ 17
Parts list for boiler sizes 700 to 1300 kW ............................................... 18
Parts list for boiler sizes 1600 to 1950 kW ............................................. 20
Parts list ................................................................................................. 22
Parts list ................................................................................................. 24
Parts list ................................................................................................. 26
4. Water quality Water quality requirements .................................................................... 28
■Heating systems with rated operating temperatures up to 100 °C
(VDI 2035) .......................................................................................... 28
■Prevention of damage through corrosion on the water side ............... 29
Using antifreeze in boilers ..................................................................... 29
5. Commissioning/service
reports
Water quality .......................................................................................... 31
Maintenance/service .............................................................................. 31
6. Specification ................................................................................................................ 33
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 34
8. Certificates EU Declaration of Conformity ................................................................ 35
Manufacturer's certificate ....................................................................... 35
9. Keyword index ................................................................................................................ 36
Index
Index
5692849

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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.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
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.
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.
Information
Symbols
5692849
Information

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Vitoplex 200, type SX2A
■Fuels: Fuel oil and natural gas
■Rated heating output 700 to 1950 kW
■Permiss. operating pressure 6 bar (0.6 MPa)
Information
Product information
5692849
Information

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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 8
• • 2. Shutting down the system................................................................................................. 8
• • 3. Opening the boiler door and cleaning cover................................................................... 9
•4. Cleaning the turbulators, heating surface, flue outlet and flue pipe............................. 9
••• 5. Checking all gaskets and packing cords on the flue gas side
••• 6. Checking the thermal insulation components on the boiler door................................. 10
•7. Inserting turbulators; securing the boiler door and cleaning cover............................. 11
••• 8. Checking connections and sensor well on the heating water side for tightness
••• 9. Checking the function of the safety equipment.............................................................. 12
••• 10. Checking the function of the pressure switch................................................................ 12
••• 11. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 12
••• 12. Checking the expansion vessel and system pressure................................................... 12
••• 13. Checking the firm seating of electrical plug-in connections and cable grommets
••• 14. Checking the thermal insulation
• • 15. Checking the water quality................................................................................................ 13
• • 16. Cleaning the sight glass in the boiler door...................................................................... 14
• • 17. Checking the mixer for ease of operation and tightness............................................... 14
• • 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
• • 21. Adjusting the burner.......................................................................................................... 14
•22. Instructing the system user.............................................................................................. 15
•23. Operating and service documents................................................................................... 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating and service instructions for the control
unit and the burner
01. Close the gas shut-off valve and open the boiler
door.
02. Check the seating of turbulators C in hot gas
flues B. Turbulator spring clips D must lock into
place behind first constriction E.
Fig. 1
ATurbulator extractor
03. Check that the ventilation air aperture in the instal-
lation room is open.
04. Fill the heating system with water and vent the
system.
Permissible operating pressure: 6 bar (0.6 MPa)
05. Enter the amount of fill water and water hardness
into the table in chapter "Checking the water qual-
ity".
!Please note
Unsuitable water quality can damage the
boiler body.
Operate boilers only with softened water.
Observe the "Water quality requirements" in
the appendix on page 28.
06. Check system pressure.
07. Check the oil level or the gas supply pressure.
08. Open the flue gas damper (if installed).
09. Check that the cleaning aperture on the flue outlet
is closed.
10. Open the shut-off valves in the oil or gas line.
11. Switch ON the mains isolator, the switch for the
heating circuit pump and the burner ON/OFF
switch, in that order. Observe the burner manufac-
turer’s operating instructions.
12. The dew point range must be cleared as quickly
as possible. For this reason prevent all heat sup-
ply to consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
!Please note
During boiler heat-up, unpleasant fumes
and odours can result from outgassing from
the thermal insulation, the thermal block
and the paint.
Ventilate the room during commissioning.
13. After the flow temperature has been reached,
switch ON the heat consumers in sequence and
change the burner over to automatic mode.
Note
Internal gas emissions from the thermal block can
lead to increased CO values in the flue gas. Con-
tinue to operate the boiler until a decline can be
clearly recognised.
14. Check all gaskets and plugs, and retighten if nec-
essary.
15. Check the boiler door and cleaning cover after
approx. 50 hours run. Tighten the 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. If installed, pull
plug-in connectors fA and lÖ from the burner.
3. Close the gas shut-off valve.
Danger
Heating water escaping under pressure will
injure bystanders.
Only open the connections on the heating water
side after the boiler has been depressurised.
Commissioning, inspection, maintenance
Commissioning the system
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!Please note
Draining the boiler with a suction pump will cre-
ate negative pressure inside the boiler.
Only drain the boiler with a suction pump when
the air vent valve is open.
Opening the boiler door and cleaning cover
Note
On gas burners, disconnect the gas supply pipe.
4x
Fig. 2
Cleaning the turbulators, heating surface, flue outlet and flue pipe
Fig. 3
Commissioning, inspection, maintenance
Shutting down the system (cont.)
5692849

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1. Pull turbulators B out towards the front with a
quick tug. For this, use turbulator extractor A from
the cleaning equipment.
2. Clean flues C and combustion chamber D with
the brush.
Remove combustion residues with a vacuum
cleaner.
3. Remove combustion residues from the flue pipe
and the flue outlet through cleaning aperture E in
the flue outlet using a vacuum cleaner.
Checking all gaskets and packing cords on the flue gas side
Checking the thermal insulation components on the boiler door
Danger
Fibre dust can be produced if working with high
temperature insulation materials that contain zir-
conium or aluminium silicate ceramic fibres. 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.
Commissioning, inspection, maintenance
Cleaning the turbulators, heating surface, flue… (cont.)
5692849

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Note
On gas burners, mount the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
4x
Fig. 4
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
1. Push turbulators C far into hot gas flues B.
Spring clip E must snap into place behind
first constriction D.
Note
This snapping into place prevents the turbulators
from slipping forward during boiler operation.
2. Tighten screws A crosswise (torque 25 Nm).
Tighten screws for cleaning cover to 7 Nm.
Checking connections and sensor well on the heating water side for tight-
ness
Commissioning, inspection, maintenance
Inserting turbulators; securing the boiler door and cleaning cover
5692849

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Check safety valves, water level and pressure limiter in
accordance with manufacturer's details.
Checking the function of the pressure switch
Installation instructions, pressure switch set
Checking the temperature controller setting if a building management system
is used (DCC system)
!Please note
Shutting down from full load can result in high
material stress and material damage.
If a system with a higher ranking building man-
agement system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller to at least 10 K below the
mechanical temperature controller.
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation Note
Check when system is cold.
Expansion vessel
1. Drain the system until the pressure gauge shows
"0". Alternatively: 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 + sup-
plement.
The supplement depends on the high limit safety
cut-out setting. The following applies:
■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 pressure 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 with softened water*1 until the charge pres-
sure 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 pressure maintain-
ing systems also provide individual protection by instal-
ling an expansion vessel for each boiler. This applies
in particular to pump controlled systems with integral
deaeration.
Boiler output kW Up to 1000 Up to 2100
Expansion
vessel
l 140 300
*1 See chapter "Water quality requirements".
Commissioning, inspection, maintenance
Checking the function of the safety equipment
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The individual protection reduces the frequency and
level of pressure fluctuations. This significantly increa-
ses the operational reliability and service life of the
system components. Failure to observe these recom-
mendations may result in damage to the boiler or to
other system components.
Only use pump controlled pressure maintaining sys-
tems that are sealed to prevent corrosion. The pres-
sure maintaining systems must be protected against
oxygen ingress into the heating water. Otherwise dam-
age to the system through oxygen corrosion can result.
Pump controlled pressure maintaining systems with
atmospheric deaeration through cyclical pressure
release effect a central post-ventilation of the heating
system. They do not provide oxygen removal in the
sense of corrosion protection as described in VDI 2035
Part 2.
Note
Check the pressure maintaining system in line with the
manufacturer's instructions.
!Please note
Cyclical pressure fluctuations and more signifi-
cant pressure differentials point towards a sys-
tem fault. Such faults result in damage to other
heating system components.
Limit pressure fluctuations to the lowest possible
differential.
Checking the firm seating of electrical plug-in connections and cable
grommets
Checking the thermal insulation
Checking the water quality
Observe the instructions in chapter "Water quality
requirements" in the appendix.
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table on
page 31.
The total hardness of the feed and top-up water must
not exceed 0.11 °dH (total value of alkaline earths
≤ 0.02 mol/m3).
The pH value should be between 9 and 10.5.
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
5692849

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Fig. 5
Note
Check the gaskets and hose connection for tightness.
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the mixer han-
dle.
2. Check the mixer for ease of operation.
3. Check the mixer for tightness. Replace the O-rings
if the mixer is leaking.
4. Snap the motorised lever into place.
Checking the function of the return temperature raising facility (if
installed)
Checking the installation room ventilation
Checking the flue pipe for tightness
Adjusting the burner
Adjust the maximum oil or gas throughput of the
burner to the rated boiler heating output.
Rated heating
output
Pressure drop on the hot gas
side
kW Pa mbar
700 270 2.7
900 460 4.6
1100 400 4.0
1300 570 5.7
Rated heating
output
Pressure drop on the hot gas
side
kW Pa mbar
1600 650 6.5
1950 850 8.5
To protect the system against dew point corrosion,
burner stage 2 (full heating output) must be set to the
rated boiler heating output. It must remain switched on,
even during the summer months (burner stage 2 on
constant standby).
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door
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Partial load operation
Set the minimum heating output for the base load
stage in accordance with the flue system. The flue sys-
tem must be suitable for the low flue gas temperatures.
In the case of frequent cycling in standby mode and for
partial loads below 40 % we recommend that you:
■Insulate the flue gas collector
■Install a motorised flue gas damper
■Set the minimum runtime of the boiler to 10 min
This extends the service life and reduces running
costs.
Operation with burner load ≥ 60 %
The minimum boiler water temperature for oil operation
is 50 °C and for gas operation 60 °C.
Adjust the return temperature raising facility to a mini-
mum of 40 °C (oil operation) or 53 °C (gas operation).
To protect the boiler, the minimum heating output in the
base load stage is set to 60 % of the rated output (see
table).
Rated heating out-
put
Minimum heating output to
be set (burner stage 1)
kW kW
700 420
900 540
1100 660
1300 780
1600 960
1950 1170
The base load stage requires a minimum flue gas tem-
perature, the value of which is subject to the design of
the flue system.
Operation with burner load ≥ 40 % and < 60 %
The minimum system temperatures (flow/return) are
60/50 °C for oil operation and 70/60 °C for gas opera-
tion.
Operation with burner load < 40 %
The minimum system temperatures (flow/return) are
60/55 °C for oil operation and 70/65 °C for gas opera-
tion.
Instructing the system user
The installer should instruct the user in the operation of
the system.
Commissioning, inspection, maintenance
Adjusting the burner (cont.)
5692849

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1. Complete and detach the customer registration
card:
■Hand the system user their section for safekeep-
ing.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the appliance has been installed. They do not
need to be retained.
Commissioning, inspection, maintenance
Operating and service documents
5692849

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The following details are required when ordering parts:
■Serial no. (see type plate A)
■Position number of the part from this parts list
Parts not shown
Pos. Part
229 Back panel retrofit kit, matching pos. 216, 217
300 Thermal insulation, small parts
301 Touch-up spray paint, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
305 Decorative adhesive tape
306 Flame tube gasket
309 Sight glass plug (accessory)
Parts lists
Ordering parts
5692849
Components

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For boiler sizes 700 to 1300 kW
011 010
012
008009001
024 025
004
005
006
007
003
308
Fig. 6
Parts lists
Parts list for boiler sizes 700 to 1300 kW
5692849
Components

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Pos. Part
001 Boiler door
003 Parts for sight glass, comprising pos. 004 to 007
004 Parts for sight glass frame
005 Gasket
006 Hose nozzle
007 Plastic hose
008 Hose pack Ø 18 mm
009 Upper insulation block
010 Lower insulation block
011 Thermal insulation mat
012 Pack GF 25 x 15
308 Logo
024 Burner plate
025 Gaskets, burner plate
Parts lists
Parts list for boiler sizes 700 to 1300 kW (cont.)
5692849
Components

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For boiler sizes 1600 to 1950 kW
012
011
008009
024 025
004
005
006
007
003
001 010
A
308
Fig. 7
AType plate
Parts lists
Parts list for boiler sizes 1600 to 1950 kW
5692849
Components