Viessmann VITOPLEX 200 Operating instructions

VIESMANN
Service instructions
for contractors
Vitoplex 200
Type SX2, 700 to 1950 kW
Oil/gas fired boiler
VITOPLEX 200
5692 727 GB 4/2007 Please keep safe.

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
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 727 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 727 GB

Commissioning, inspection, maintenance
Steps –commissioning, inspection and maintenance .................................. 5
Further details regarding the individual steps .............................................. 7
Parts lists .................................................................................................. 17
Appendix
Water quality requirements ......................................................................... 22
Commissioning/service reports............................................................... 25
Specification............................................................................................. 26
Certificates
Declaration of conformity ............................................................................ 27
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 28
Keyword index .......................................................................................... 29
Index
4
Index
5692 727 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 1. Commissioning the system .............................................. 7
•• 2. Shutting down the system ................................................. 8
•3. Opening the boiler door and clean-out cover............. 9
•4. Cleaning the turbulators, heating surface, flue
outlet and flue pipe............................................................... 10
•• 5. Checking all seals/gaskets and packing cords on
thefluegasside
•• 6. Checking the thermal insulation of the boiler door
•7. Inserting the turbulators, fitting the boiler door
and clean-out cover ............................................................. 10
•• 8. Checking connections and sensor well for leaks
on heating water side
•• 9. Checking the function of the safety equipment......... 12
•• 10. Checking the diaphragm expansion vessel and
system pressure.................................................................... 12
•• 11. Checking the tightness of electrical plug-in
connectors and cable grommets
•• 12. Checking the thermal insulation
••13. Checking the water quality................................................ 13
•• 14. Cleaning the sight glass in the boiler door ................. 14
•15. Checking the mixer for ease of operation and leaks 15
•16. Checking the function of the return temperature
raising facility (if installed)
•• 17. Checking the installation room ventilation
•• 18. Checking the flue pipe for soundness
•19. Adjusting the burner............................................................ 15
•20. Instructing the system user .............................................. 16
Steps –commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 727 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•21. Operating and service documents ................................. 16
Steps –commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 727 GB

Commissioning the system
Operating and service instructions for the control unit and the burner
1. Close the gas shut-off valve and
open the boiler door.
2. Check that the turbulators Care
pushed into the hot gas flues B,
that safety spring Dsnaps into
place behind the first resistance
E.
ATurbulator extractor
3. Check that the installation room
ventilation aperture is open.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 727 GB

4. Fill the heating system with water
and ventilate the system.
Permissible operating pressure:
6bar
!Please note
Unsuitable water qualities
can result in boiler body
damage.
According to VDI Directive
2035, the boiler must be
filled and operated with
water, the sum of alkaline
earths of which must not
exceed 0.02 mol/m
3
.
Observe the "Water quality
requirements" on page 22.
Note
Record the fill volume and water
hardness on page 13.
5. Check the system pressure.
6. Check the fuel oil level or the gas
supply pressure.
7. Openthefluegasdamper(if
installed).
8. Check that the cleaning aperture
ontheflueoutletisclosed.
9. Open the gas or oil supply line
shut-off valves.
10. Switch ON the main isolator, the
switch for the heating circuit pump
and the burner ON/OFF switch in
theorderlistedhere(observethe
burner manufacturer's instruc-
tions).
11. When heating the system from
cold(alsowhenrestartingafter
maintenance and cleaning work),
prevent all heat transfer to consu-
mers, to clear the dew point range
as quickly as possible.
12. After the flow temperature has
been reached, switch ON the heat
consumers in sequence and
change the burner over to auto-
matic mode.
13. Check all gaskets/seals and plugs
and retighten, if necessary.
14. Check the boiler door and clean-
out cover after approx. 50 hours
and retighten all screws.
Shutting down the system
1. Switch OFF the main isolator or the
power supply, and safeguard
against unauthorised reconnection.
2. Interrupt the burner power supply.
For this, pull the power supply
plug-in connectors fA and lÖ (if
installed) from the burner.
3. Close the gas shut-off valve.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 727 GB

Danger
Heating water escaping under
pressure will injure bystanders.
Only open the connections on
the heating water side after the
boiler has been depressurised.
!Please note
Draining the boiler with a suc-
tion pump will create negative
pressure inside the boiler.
Drain the boiler with a suction
pump only when the air vent
valve has been cracked open.
Opening the boiler door and clean-out cover
Note
In case of gas burners, remove the gas supply pipe.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 727 GB

Cleaning the turbulators, heating surface, flue outlet and flue
pipe
1. Remove turbulators Bwith a
quick tug towards the front; for this,
use turbulator extractor A,which
is part of the cleaning equipment.
2. Clean flues Cand combustion
chamber Dwith the brush.
Remove combustion residues with
a vacuum cleaner.
3. Remove combustion residues from
theflueandtheflueoutletthrough
the clean-out aperture in flue outlet
Eusing a vacuum cleaner.
Inserting the turbulators, fitting the boiler door and clean-out
cover
Note
Fit the gas supply pipe in case of gas burners.
Danger
Escaping gas leads to a risk of explosion.
Test the soundness of all gas connections.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 727 GB

Push the turbulators Cinto the hot
gas flues Bso far, that safety spring
Esnaps into place behind the first
resistance D.
Tighten screws Adiagonally.
Note
This snapping into place prevents the
turbulators from slipping forward dur-
ing boiler operation.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 727 GB

Checking the function of the safety equipment
Check the safety valves, the water
level and pressure limiters in accor-
dance with manufacturer's details.
Checking the diaphragm expansion vessel and system pres-
sure
Observe the manufacturer's documentation regarding the diaphragm
expansion vessel.
Note
Carry out this test on a cold system.
Pump-controlled pressure maintaining systems
In heating systems with automatic
pressure maintaining systems, and in
particular pump-controlled systems,
with integral degassing, we recom-
mend the installation of a diaphragm
expansion vessel (DEV) as individual
boiler protection.
Boiler out-
put
kW up to
1000
up to
2000
DEV litres 140 300
This reduces the frequency and level
of pressure fluctuations. This contri-
butes considerably to improved
operational reliability and a longer
service life of the system compo-
nents. Damage to the boiler or to
other system components may result
if these recommendations are not fol-
lowed.
Furthermore ensure that only pump-
controlled pressure maintaining sys-
tems that are sealed against corro-
sion and protected against oxygen
ingress into the heating water are
used. Otherwise damage to the sys-
tem through oxygen corrosion can
result.
Pump-controlled pressure maintain-
ing systems with atmospheric degas-
sing through cyclical pressure release
create a central post-venting of the
heating system. However, this does
not represent oxygen removal in the
sense of corrosion protection to VDI
2035 sheet 2.
Note
Carry out all checks in accordance
with manufacturer's instructions.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 727 GB

!Please note
Cyclical pressure fluctuations
and more significant pressure
differentials point towards a
system fault. Such faults will
result in damage to other heat-
ing system components.
Limit pressure fluctuations to
the lowest possible differential.
Diaphragm expansion vessel
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure,
until the pressure gauge indicates
"0".
Note
The inlet pressure of the diaphragm
expansion vessel (p0) comprises
the static system pressure (pSt)(=
static head) and a supplement (p0
=pSt + supplement).
The supplement is subject to the
adjustment of the high limit safety
cut-out. For a high limit safety cut-
out set to
&100°C:0.2bar
&110°C:0.7bar.
2. If the inlet pressure of the dia-
phragm expansion vessel is lower
than the static system pressure,
topupwithsufficientnitrogento
raise the inlet pressure higher (0.1
to 0.2 bar) than the static system
pressure.
The static pressure corresponds to
the static head.
3. Topuptheheatingsystemwith
water until the filling pressure of a
cool system is higher (0.1 to 0.2
bar) than the inlet pressure of the
diaphragm expansion vessel.
Permiss. operating pressure: 6 bar.
Checking the water quality
Enter the volume of the top-up water and the total hardness of the feed and boil-
er water into the table.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 727 GB

Count Fill and
top-up
water
Tot al
water vo-
lume
Total hardness pH value Date
Feedwa-
ter
Boiler
water
m
3
m
3
m
3
°dH °dH
The total hardness of the feed and top-up water must not exceed 0.02 mol/m 3.
The pH value should be between 8.2 and 9.5.
Cleaning the sight glass in the boiler door
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 727 GB

Note
Check the gaskets and hose connec-
tion for leaks.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from
the mixer handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-rings if the mixer leaks.
4. Snap the motorised lever into
place.
Adjusting the burner
Adjust the maximum oil or gas
throughput of the burner to the rated
boiler output.
Rated out-
put
Hot gas pressure
drop
kW Pa mbar
700 270 2.7
900 460 4.6
1100 400 4.0
1300 570 5.7
1600 530 5.3
Rated out-
put
Hot gas pressure
drop
kW Pa mbar
1950 850 8.5
To protect the system against dew
point corrosion, the 2nd burner stage
(full capacity) must be set to the rated
boiler output and must not be
switched OFF during summer time
(stage 2 constant standby).
Operation with burner load ≥60 %
The minimum boiler water tempera-
ture for operation with oil is 50 ºC and
for gas 60 ºC.
Adjust the return temperature raising
facility to a minimum temperature of
40 ºC (operation with oil) or to 53 °C
(operation with gas).
To protect the boiler, the minimum out-
put in the base load stage is set to
60 % of the rated output (see table).
Rated output Minimum output
to be selected
(burner stage 1)
kW kW
700 420
900 540
1100 660
1300 780
1600 960
1950 1170
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 727 GB

A minimum flue gas temperature is
required for the base load stage, the
value of which is subject to the design
ofthefluegassystem.
Operation with burner load <60 %
The minimum boiler water tempera-
ture for operation with oil is 60 ºC and
for gas 65 ºC.
Adjust the return temperature raising
facility to a minimum temperature of
53 °C.
Set the minimum heating output for
thebaseloadstageaccordingtothe
conditions of the flue gas system.
Note that the flue gas system must be
suitable for the low flue gas tempera-
tures that may occur.
Instructing the system user
The installer must instruct the user in
the operation of the system.
Operating and service documents
1. Complete and detach the customer
registration card:
&Hand the system user this part
for safekeeping.
&Retain the heating contractor's
part.
2. File all parts lists, operating and
service instructions in the folder
andhandthisovertothesystem
user.
The installation instructions are no
longer required after the installa-
tion and, therefore, do not need to
be retained.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 727 GB

Information regarding the ordering
of spare parts
Quote the part and serial no. (see
type plate) and the item no. of the
required part (as per this parts list).
Obtain standard parts from your local
supplier.
Parts
001 Door
002 Stud
003 Sight glass pack, comprising
items 004 to 008
004 Hose
005 Sight glass closure
006 Sight glass with item 007
007 Seal ring
008 Hose ferrule
009 Hose pack Ø 18 mm
010 Upper insulating block
011 Lower insulation block
012 Thermal insulation mat
013 Packing GF 25 × 15
014 Turbulator
015 Gasket
016 Clean-out cover
017 Packing
018 Sensor well
200 Cover panel, front
201 Cover panel, back
202 Top front panel (only for 1600 to
1950 kW)
203 Top front and back panel
204 Front panel, bottom
205 Back panel, bottom
206 Side panel
207 Side panel, control unit
208 Centre rail
209 Front r.h. rail
210 Front l.h. rail
211 Back r.h. rail
212 Back l.h. rail
213 Thermal insulation jacket
214 Thermal insulation jacket, centre
(only for 1100 to 1950 kW)
215 Thermal insulation mat, back
216 Insulation mat, l.h. back
217 Insulation mat, r.h. back
218 Mounting panel, back
219 Mounting panel
220 Channel retainer
221 Top part, cable duct
222 Bottom part, cable duct
223 Edge protector
224 Cover, sensor coupling
225 Front insulation mat
226 Insulation mat, l.h. front
227 Insulation mat, r.h. front
Wearing part
019 Cleaning brush
Accessories
020 Brush handle
021 Extension piece
022 Turbulator extractor
023 Burner plate pack
024 Packing GF 9 × 7
Parts not shown
300 Thermal insulation pack
301 Touch-up spray, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
305 Decorative adhesive tape
AType plate, optionally on the r.h.
or l.h. side
BBoiler control unit (see parts list in
the service instructions of the boil-
er control unit)
CBurnercable(seepartslistinthe
service instructions of the boiler
control unit)
Parts lists
17
Parts lists
5692 727 GB

Parts lists (cont.)
18
Parts lists
5692 727 GB

Parts lists (cont.)
19
Parts lists
5692 727 GB

Parts lists (cont.)
20
Parts lists
5692 727 GB