Viessmann VITOPLEX 200 Type SX2A User manual

Installation instructions
for contractors
VIESMANN
Vitoplex 200
Type SX2A, 90 to 560 kW
Oil/gas boiler
VITOPLEX 200
5457357 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
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1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
System examples .................................................................................. 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
3. Installation sequence Siting and levelling the boiler ................................................................. 7
Changing the boiler door opening ......................................................... 8
Combustion chamber sight glass ........................................................... 8
■Mounting the combustion chamber sight glass .................................. 8
■Closing off the sight glass aperture on burners without ventilation
connection .......................................................................................... 9
Connections on the heating water side .................................................. 10
Making the safety connection and testing for tightness ......................... 11
Connections on the flue gas side ........................................................... 12
Fitting the thermal insulation .................................................................. 12
■Boiler body thermal insulation ............................................................ 13
■Rear thermal insulation ....................................................................... 14
■Side panels and burner cables (90 to 350 kW) .................................. 15
■Side panels and burner cables (440 to 560 kW) ................................ 17
■Front panels ........................................................................................ 19
■Preparing for the control unit installation ............................................ 19
■Back panels ........................................................................................ 22
■Top panels and type plate ................................................................... 23
■Control unit fascia ............................................................................... 24
Mounting the burner ............................................................................... 24
Pressure switch ..................................................................................... 25
■Pressure switch .................................................................................. 25
Information on commissioning ............................................................... 25
4. Specification ................................................................................................................ 26
Index
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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
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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 200, type SX2A
■Fuels: Fuel oil and natural gas
■Permissible operating pressure: Up to 560 kW 4 bar
(0.4 MPa); from 700 kW 6 bar (0.6 MPa)
■Rated heating output 90 to 560 kW
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
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(300)
200 (100)
500 (50)
400 a
b
500 (50)
AB
C
Fig. 1
ABoiler
BBurner
CAdjustable anti-vibration feet (accessories)
Dimensions in brackets are minimum clearances.
100
20
28
M12
Fig. 2
Rated heating output kW 90 120 150 200 270 350 440 560
a*1 mm 1100 1400 1600
bmm Observe the installed burner length.
Adjustable anti-vibration feet
Permissible load kg 2000
Quantity pce 4
*1 Maintain this space in front of the boiler to enable the removal of turbulators or for cleaning hot gas flues.
Clearance dimensions
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2.
1.
E
Fig. 3
1. Insert adjusting screws E into the base rails.
Note
The adjusting screws and sight glass closure can
be found inside the combustion chamber.
2. Level the boiler horizontally. No special founda-
tions are required.
Note
We recommend siting the boiler on adjustable anti-
vibration feet C (see chapter "Clearance dimen-
sions").
Adjustable anti-vibration feet
Insert adjustable feet into the base rails from below.
Siting and levelling the boiler
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A
A
B
C
C
D
B
Fig. 4
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:
When the boiler door is closed, sealing frame B must
press centrally onto gasket D of the boiler door (see
detail). 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
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1.
2.
A
Fig. 5
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. 6
1. Check that the plug is a precise fit. If necessary,
enlarge hole in insulation block.
Combustion chamber sight glass (cont.)
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2. Apply adhesive all around the plug. Insert plug.
Note
Adhesive drying time: 24 hours
3.
4.
Fig. 7
Connections on the heating water side
Note
Install all pipe connections free of load and torque
stress.
GAB CDF
H
Fig. 8 90 to 270 kW
ABoiler return, DN 65
BFemale connection for Therm-Control temperature
sensor (NTC 10 kΩ), R ½
CFemale connection for pressure gauge, R ½
DSafety connection (safety valve)
FBoiler flow, DN 65
GFemale connection for boiler water temperature
sensor, high limit safety cut-out and temperature
controller
HDrain, R 1¼
Combustion chamber sight glass (cont.)
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H
GA CD F E
H
B
Fig. 9 350 to 560 kW
ABoiler return
For 350 kW: DN 80
For 440 and 560 kW: DN 100
BFemale connection for Therm-Control temperature
sensor (NTC 10 kΩ), R ½
CFemale connection for fitting assembly, R ½
DSafety connection (safety valve)
EFemale connection for high limit safety cut-out
(instead of flash trap), R ½
FBoiler flow
For 350 kW: DN 80
For 440 and 560 kW: DN 100
GFemale connection for boiler water temperature
sensor, high limit safety cut-out and temperature
controller
HDrain, R 1¼
Making the safety connection and testing for tightness
Safety equipment block installation instructions
Install the safety lines.
Safety connection
■90 to 350 kW R 1¼
■440 and 560 kW R 1½
Permiss. operating pres-
sure:
4 bar (0.4 MPa)
Test pressure: 5.2 bar (0.52 MPa)
Low water indicator
The boiler control unit included as standard prevents
impermissible heating in the case of water shortage.
According to EN 12828, a low water indicator can
therefore be omitted for Vitoplex 300 boilers up to 300
kW (except in attic heating centres).
Therm-Control start-up control (with temperature
sensor NTC 10 kΩ)
A shunt pump for raising the return temperature is not
required.
During the start-up phase, ensure that the heating cir-
cuit flow rate is reduced to no more than 50 % by
means of the heating circuit control unit or heating cir-
cuit pumps. This applies during commissioning as well
as after night or weekend shutdowns. For multi boiler
systems, reduce to no more than 50 % of the smallest
boiler.
The heating circuit control unit or the heating circuit
pumps are regulated by means of the factory-fitted
Therm-Control temperature sensor (NTC 10 kΩ). For
further details regarding the Therm-Control start-up
system, see the technical guide.
For installation, see separate installation instructions.
Note
Equip the boilers with a safety valve that is type-tested
according to EN 4126. The valve must be marked in
accordance with the system version.
Install all pipe connections free of load and torque
stress.
Connections on the heating water side (cont.)
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!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 and guideline VDI 2035).
Connections on the flue gas side
ØD Ø10 mm
2-3 x ØD
Fig. 10
Vitoair installation instructions
1. Connect the flue outlet with the shortest possible
run to the chimney and maintain a slight rise.
External Ø, flue outlet:
90 and 120 kW 178 mm
150 to 350 kW 198 mm
440 to 560 kW 248 mm
2. Create a test port.
3. Seal in and thermally insulate the flue pipe (all con-
nections/joints must be gas-tight).
Fitting the thermal insulation
Note
All components required for fitting the thermal insula-
tion can be found in the thermal insulation box.
Making the safety connection and testing for… (cont.)
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Boiler body thermal insulation
3.
1.
2.
4.
B A
Fig. 11
ABlack side outwards
Note
Remove bag B containing the type plate and keep
safe. This will be required later.
Fitting the thermal insulation (cont.)
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Rear thermal insulation
2.
1.
Fig. 12
Note
Check that the serial number on the type plate
matches the serial number stamped into the back
panel of the boiler.
Fitting the thermal insulation (cont.)
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Side panels and burner cables (90 to 350 kW)
Note
Burner cables fA and lÖ are included.
M6
1. 2. 4x
1.
4.
4x
3.
Fig. 13
Note
Using screws, secure the lower rails behind the boiler
base rails.
Fitting the thermal insulation (cont.)
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41
90
8x
5.
4.
3.
2.
1.
Fig. 14
Note
Route burner cables fA and lÖ along the side of the
boiler where the boiler door hinges are located.
Fitting the thermal insulation (cont.)
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Side panels and burner cables (440 to 560 kW)
Note
Burner cables fA and lÖ are included.
M6
1.
3.
1.
4.
8x
2. 4x
Fig. 15
Note
Using screws, secure the lower rails behind the boiler
base rails.
Fitting the thermal insulation (cont.)
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41
90
12x
6.
5. 3.
4.
2.
1.
A
Fig. 16
ASide panels with screw holes at the rear
Note
Route burner cables fA and lÖ along the side of the
boiler where the boiler door hinges are located.
Fitting the thermal insulation (cont.)
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Front panels
3,9 x 9,5
3,9 x 9,5
2
3.
2. 1.
4.
5.
6.
Fig. 17
Preparing for the control unit installation
Connections to the control unit back panel
Boiler control unit installation instructions
Note
Boiler water temperature sensor § is supplied in the
control unit pack.
The Therm-Control temperature sensor (NTC 10 kΩ)
aJ is supplied separately.
The boiler coding card and logo are supplied with the
product pack.
Push the measuring probes, boiler water temperature
sensor and Therm-Control temperature sensor
(NTC 10 kΩ) as far as they will go into the sensor
wells.
Power supply plug fÖ is supplied with the control unit.
!Please note
Damaged capillary tubes will result in malfunc-
tions of the measuring probes.
Never kink the capillary tubes.
Fitting the thermal insulation (cont.)
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2.
1.
6 x 12
Fig. 18
Note
Screws (6 x 12) can be found with the control unit fas-
cia (packed separately with the thermal insulation).
A
1.
1.
2.
2.
Fig. 19
ABoiler coding card
Fitting the thermal insulation (cont.)
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