Viessmann VITOPLEX 200 Type SX2A User manual

Installation instructions
for contractors
VIESMANN
Vitoplex 200
Type SX2A, 700 to 1950 kW
Oil/gas boiler
VITOPLEX 200
5457380 GB 7/2018 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
Thermal insulation components ............................................................. 7
■Thermal insulation pack 1 ................................................................... 7
■Thermal insulation pack 2 ................................................................... 8
■Thermal insulation pack 3 ................................................................... 9
■Components in the combustion chamber ........................................... 10
3. Installation sequence Siting and levelling the boiler ................................................................. 11
Changing the boiler door opening ......................................................... 12
Combustion chamber sight glass ........................................................... 12
■Mounting the combustion chamber sight glass .................................. 12
■Closing off the sight glass aperture on burners without ventilation
connection .......................................................................................... 13
Connections on the heating water side .................................................. 14
Making the safety connection and testing for tightness ......................... 15
Fitting the thermal insulation .................................................................. 15
■Boiler body thermal insulation ............................................................ 16
■Wing screws in the top and base rails ................................................ 17
■Front and back rails ............................................................................ 18
■Centre rail ........................................................................................... 19
■Aligning the rails ................................................................................. 20
Mounting the control unit ....................................................................... 21
■Control unit mounting bracket, control unit back section and burner
cables ................................................................................................. 21
■Remaining side panels ....................................................................... 25
■Cable trunking .................................................................................... 25
Fitting additional thermal insulation ....................................................... 26
■Front thermal insulation and front panels ........................................... 26
■Thermal insulation (back) and back panels ........................................ 27
■Covers ................................................................................................ 28
■Type plate ........................................................................................... 29
Connections on the flue gas side ........................................................... 30
Mounting the burner ............................................................................... 30
Pressure switch ..................................................................................... 31
■Pressure switch .................................................................................. 31
Commissioning information ................................................................... 32
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
■Rated heating output 700 to 1950 kW
■Permiss. operating pressure 6 bar (0.6 MPa)
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
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500
(50)
800
(50)
400
a
200 (100)
b
(300)
Fig. 1
c
e
d
Fig. 2
ABoiler
BBurner
CAnti-vibration boiler supports (accessories)
DBoiler control unit
Dimensions in brackets are minimum dimensions, e.g.
50 mm, if control unit D is mounted on the opposite
side.
Rated heating output kW 700 900 1100 1300 1600 1950
a*1 mm 2000 2200 2000 2200 2650
bmm Observe the installed burner length
Anti-vibration boiler supports
Permissible load kg 3000 3105 4000 4668 6004
c (front) / number mm/pce 750/2 500/2 500/2 667/2 834/2
c (back) / number mm/pce 750/2 334/2 334/2 500/2 667/2
d mm 30 100
e (unstressed) mm 42
e (stressed) mm 37
*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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The thermal insulation and casing are supplied in 3
packs. The following is a list of components in the indi-
vidual packs.
Thermal insulation pack 1
12
2
3
3
Fig. 3
1Thermal insulation mat, back
2Thermal insulation jacket
3Side panel
Thermal insulation components
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Thermal insulation pack 2
qO 4 56
4
qO
qI
qU qZ
qT
qR
qE
3qW qQ qP
7
9
3
8
Fig. 4
3Side panel
4Cover panel top back
5Thermal insulation mat, back left
6Thermal insulation mat, back right
7Back panel, bottom
8Cable trunking retainer
9Thermal insulation jacket, centre
qP Mounting bracket fascia
qQ Mounting bracket
qW Mounting bracket rear
qE Side panel, control unit
qR Front panel, bottom
qT Thermal insulation mat, front
qZ Thermal insulation mat, front right
qU Thermal insulation mat, front left
qI Front/back panel, top
qO Cover panel top front
Thermal insulation components (cont.)
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Thermal insulation pack 3
eQ
eW
wP wQ
wW
eW
eP
wE
wR
wT
wI wO
wZ
wU
Fig. 5
wP Rail, back left
wQ Cover, sensor coupling
wW Rail, back right
wE Cable trunking, lower section
wR Cable trunking, upper section
wT Bag of burner cables
eP Rail, front right
eQ Rail, front left
eW Centre rail, 2 pce
Bag of small parts
wZ Strain relief
wU Spring hooks
wI Wing screw
wO Screws
Thermal insulation components (cont.)
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Components in the combustion chamber
eT eZ
eU eI eO
rP
Fig. 6
eT Plastic hose
eZ Hose nozzle
eU Sight glass frame
eI Sight glass
eO Sight glass frame gasket
rP Bag of adjusting screws
Thermal insulation components (cont.)
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Required materials:
■Adjusting screws from the combustion chamber
1.
2.
2.
Fig. 7
1. Insert adjustable screws A into the base rails.
Position a plate, e.g. a flat steel strip, underneath
each adjusting screw to distribute the load evenly.
2. Level the boiler horizontally. No special founda-
tions are required.
Note
We recommend installing the boiler on anti-vibration
boiler supports C (see page 6).
Anti-vibration boiler supports
Floor undulations must not be greater than 1 mm to
ensure that the spring elements are loaded evenly.
Position the boiler supports underneath the boiler by
placing them centrally under the base rails.
When setting the boiler down less than square on, a
boiler support can temporarily be overloaded. To aid
installation, support the boiler on timbers (□ 35 mm).
Position these at the front, centre and end of each
boiler support.
Siting and levelling the boiler
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A
A
B
C
C
D
B
Fig. 8
By repositioning bolts A the door can be hinged on
the right.
Note
During installation observe the following: When the
boiler door is closed, sealing frame B must press cen-
trally onto gasket D of the boiler door (see detail). If
necessary, align mounting bracket C.
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. 9
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. 10
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. 11
Connections on the heating water side
Note
Install all pipe connections free of load and torque stress.
Fig. 12
ADrain, R 1¼
BFemale connection for condensate drain, R ½
CFemale connection for boiler water temperature
sensor, high limit safety cut-out and temperature
controller, R ¾
DBoiler flow
700 and 900 kW: DN 100
1100 and 1300 kW: DN 125
1600 and 1950 kW: DN 150
EFemale connection for high limit safety cut-out,
R ½ (in place of flash trap)
Combustion chamber sight glass (cont.)
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FSafety connection (safety valve), see chapter
"Making the safety connection and checking tight-
ness"
GBoiler return
700 and 900 kW: DN 100
1100 and 1300 kW: DN 125
1600 and 1950 kW: DN 150
HFemale connection for fitting assembly, R ½
Making the safety connection and testing for tightness
Install the safety lines.
Safety connection
700 and 900 kW DN 50 PN 16
1100 to 1950 kW DN 65 PN 16
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.
!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).
Fitting the thermal insulation
Note
Small parts and burner cables are supplied in separate bags inside thermal insulation pack 3.
Required parts
Parts from thermal insulation pack 1
■Thermal insulation jackets
■Side panels
Parts from thermal insulation pack 2
■Thermal insulation jacket, centre
Parts from thermal insulation pack 3
■Rail, back left
■Rail, back right
■Spring hooks
■Wing screws
■Rail, front right
■Rail, front left
■Centre rails
Connections on the heating water side (cont.)
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Boiler body thermal insulation
3.
1.
B A
2.
Fig. 13
ABlack side outwards
Note
Remove bag B 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. Remove thermal insulation jacket from the upper
boiler cover.
3. Connect the thermal insulation jacket with an over-
lap.
Fitting the thermal insulation (cont.)
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Wing screws in the top and base rails
Wing screws are inside the small parts bag in thermal
insulation pack 3.
2-3mm
16x
1.
Fig. 14
ATop rail
BBase rail
Fitting the thermal insulation (cont.)
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Front and back rails
Rails are supplied in thermal insulation pack 3.
4x
4x
2.
1.
Fig. 15
Note
The front rails are equipped with trim strips A.
Fitting the thermal insulation (cont.)
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Centre rail
Rails are supplied in thermal insulation pack 3.
1.
2x
Fig. 16
Fitting the thermal insulation (cont.)
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Aligning the rails
Side panels are supplied in thermal insulation packs 1
and 2.
a
a
4x
3.
2.
1.
Fig. 17
Align side panels in parallel (see enlarged diagram).
Align and secure the rails.
Fitting the thermal insulation (cont.)
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