Viessmann Vitoplex 100 Service Instructions Manual

Brand: Viessmann

Model: Vitoplex 100

Category: Water heaters & boilers

Type: Service Instructions Manual

Viessmann Vitoplex 100 is a powerful oil/gas boiler designed for heating medium- to large-sized residential and commercial buildings. Its efficient operation and range of features make it a reliable choice for various heating needs. It boasts a heating capacity of 150 to 620 kW, ensuring ample heating power even for extensive spaces.

Service instructions

for contractors

VIESMANN

Vitoplex 100

Type PV1, 150 to 620 kW

Oil/gas boiler

For applicability, see the last page

VITOPLEX 100

5692 701 GB 3/2013 Please keep safe.

Please follow these safety instructions closely to prevent accidents and mate-

rial 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 envi-

ronmental pollution.

Note

Details identified by the word "Note" con-

tain additional information.

Target group

These instructions are exclusively inten-

ded for qualified contractors.

■ Work on gas installations must only be

carried out by a registered gas fitter.

■ Work on electrical equipment must

only be carried out by a qualified elec-

trician.

■ The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following when working on

this system:

■ Statutory regulations regarding the

prevention of accidents

■ Statutory regulations regarding envi-

ronmental 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

■ Gas Safety (Installation & Use) Regu-

lations

– the appropriate Building Regulation

either the Building regulations, the

Building Regulation (Scotland), Build-

ing Regulations (Northern Ireland),

– the Water Fittings Regulation or

Water Bylaws in Scotland,

– the current I.E.E. Wiring Regula-

tions.

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Do not smoke. Prevent naked

flames and sparks. Do not

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.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 701 GB

If you smell flue gas

Danger

Flue gas can lead to life-threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate the installation site.

■ Close all doors in the living

space.

Flue systems and combustion air

Ensure that flue systems are clear and

cannot be sealed, for instance due to

accumulation of condensate or other

causes. Ensure a sufficient supply of

combustion air.

Instruct system users that subsequent

modifications to the building characteris-

tics are not permissible (e.g. cable/pipe-

work routing, cladding or partitions).

Danger

Life-threatening poisoning

caused by carbon monoxide in

the flue gas occurs as a result of

leaking or blocked flue systems

or an insufficient supply of com-

bustion air.

Ensure the flue system is in

proper working order. It must not

be possible to close apertures for

interconnected combustion air

supply.

Extractors

Operating appliances that extract air to

the outside (cooker hoods, extractors, air

conditioning units, etc.) can create neg-

ative pressure. If the boiler is operated at

the same time, this can lead to reverse

flow of the flue gas.

Danger

The simultaneous operation of

the boiler and appliances that

extract air to the outside can

result in life threatening poison-

ing due to reverse flow of the flue

gas.

Fit an interlock circuit or take suit-

able steps to ensure a sufficient

supply of combustion air.

Working on the system

■ Where gas is used as the fuel, close

the main gas shut-off valve and safe-

guard it against unintentional reopen-

ing.

■ Isolate the system from the power sup-

ply (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 recon-

nection.

!Please note

Electronic assemblies can be

damaged by electrostatic dis-

charge.

Prior to commencing any 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 function can compromise

the safe operation of your sys-

tem.

Defective components must be

replaced with genuine

Viessmann spare parts.

Safety instructions

Safety instructions (cont.)

5692 701 GB

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that

have not been tested together

with the system can compromise

its function. Installing non-author-

ised components and making

non-approved modifications or

conversions can compromise

safety and may invalidate our

warranty.

For replacements, use only orig-

inal spare parts supplied or

approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5692 701 GB

Product information

Intended use......................................................................................................... 6

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 7

Further details regarding the individual steps....................................................... 9

Parts lists............................................................................................................ 19

Water quality

Water quality requirements.................................................................................. 22

Using antifreeze in boilers.................................................................................... 25

Commissioning/service reports........................................................................ 27

Specification....................................................................................................... 28

Certificates

Declaration of conformity...................................................................................... 29

Keyword index.................................................................................................... 30

Index

5692 701 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions 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 pur-

pose other than the heating up of heating

water shall be deemed inappropriate.

Intended use presupposes that a fixed

installation in conjunction with permissi-

ble components designed for this pur-

pose has been carried out.

Every other use will be deemed to be

inappropriate. Any resulting losses are

excluded from the manufacturer's liabil-

ity.

Any usage beyond this must be

approved by the manufacturer for the

individual case.

Intended use also includes the adher-

ence to maintenance and inspection

intervals.

Product information

Intended use

5692 701 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Commissioning the system........................................... 9

• • 2. Shutting down the system............................................. 10

• • 3. Closing the Vitoair draught stabiliser (if installed)...... 10

• • 4. Opening the boiler door and cleaning cover............... 10

•5. Cleaning the turbulators, heating surface, flue outlet

and flue pipe.................................................................... 11

••• 6. Checking all gaskets and packing cords on the flue

gas side

••• 7. Checking the thermal insulation components on the

boiler door

•8. Inserting the turbulators................................................ 12

• • 9. Securing the boiler door and cleaning cover............... 13

••• 10. Checking connections and sensor well for leaks on

the heating water side

••• 11. Checking the function of the safety equipment........... 13

••• 12. Checking the expansion vessel and system pressure 14

••• 13. Checking the firm seating of electrical plug-in

connections and cable grommets

••• 14. Checking the thermal insulation

• • 15. Checking the water quality............................................ 15

• • 16. Cleaning the sight glass in the boiler door.................. 17

••• 17. Checking the mixer for ease of operation and

tightness.......................................................................... 17

••• 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

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 701 GB

Commissioning steps

Inspection steps

Maintenance steps Page

••• 21. Checking the Vitoair draught stabiliser (if installed)... 17

• • 22. Adjusting the burner...................................................... 17

•23. Instructing the system user........................................... 18

•24. Operating and service documents................................ 18

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5692 701 GB

Commissioning the system

Operating and service instruc-

tions for the control unit and the

burner

01. Check that the turbulators are fully

inserted into the hot gas flues (see

page 12); open the boiler door for

this.

02. Check that the installation room

vent is open.

03. Fill the heating system with water

and vent the system.

Permissible operating pressure:

5 bar (0.5 MPa)

!Please note

Scaling and boiler damage

may result if the system is

not operated with fully soft-

ened heating water.

Operate boilers only with

softened water.

Observe the instructions in

chapter "Water quality

requirements".

04. Enter the amount of fill water and

water hardness into the table in

chapter "Checking the water qual-

ity".

05. Check the system pressure.

06. Check the oil level or the gas supply

pressure.

07. Open the flue gas damper (if instal-

led).

08. Check that the cleaning aperture on

the flue outlet is closed.

09. Open the shut-off valves in the oil or

gas line.

10. Switch ON the mains isolator, the

switch for the heating circuit pump

and the burner ON/OFF switch in

this order (observe the burner man-

ufacturer's instructions).

11. When heating the system from cold

(also when restarting after mainte-

nance and cleaning work), prevent

all heat supply to heat consumers,

to clear the dew point range as

quickly as possible.

!Please note

During boiler heat-up,

unpleasant fumes and

odours can result from out-

gassing from the thermal

insulation, the heating block

and the paint.

Vent the room during com-

missioning.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 701 GB

12. After the flow temperature has been

reached, switch ON the heat con-

sumers in sequence and change the

burner over to automatic mode.

!Please note

When testing the flue gas for

CO, internal gases being

expelled from the heating

block can cause higher val-

ues.

Continue to operate the

boiler until a decline can be

clearly recognised.

13. Check all gaskets and plugs, and

retighten if necessary.

14. Check the boiler door and cleaning

cover after approx. 50 hours run and

retighten all screws.

Danger

Opening the connections on the

heating water side whilst the

boiler is under pressure can

cause personal injury.

First depressurise the boiler.

Only drain the boiler with a suc-

tion pump when the air vent valve

is open.

Shutting down the system

Danger

Only open the connections on the

heating water side after the boiler

has been depressurised.

Only drain the boiler with a suc-

tion pump when the air vent valve

is open.

Closing the Vitoair draught stabiliser (if installed)

1. Start the burner. 2. With the pre-purge running, shut

down the system. The control disc will

then be closed.

Opening the boiler door and cleaning cover

Note

On gas burners, remove the gas supply

pipe.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Cleaning the turbulators, heating surface, flue outlet and flue

pipe

CBA

1. Remove turbulators A without

applying force.

2. Clean flues B and combustion

chamber C with the brush.

Remove combustion residues with a

vacuum cleaner.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

3. Remove combustion residues from

the flue and the flue outlet through the

cleaning aperture in outlet D using a

vacuum cleaner.

Inserting the turbulators

!Please note

Burner adjustments and specific

system conditions can cause the

turbulators to move forward,

which may result in them being

burnt. This can also lead to dam-

age to the thermal insulation on

the boiler door.

Before insertion, the turbulators

must be slightly bent (see

steps).

10-15°

1. Push turbulators A approx. ¼ of

their length into hot gas pipes B.

2. Bend turbulators approx. 10-15°.

3. Push the turbulators into the hot gas

flues as far as they will go. When

doing this, check the prestress.

Note

Ensure that turbulators cannot easily

be pulled out of the hot gas flues.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Securing the boiler door and cleaning cover

Note

Mount the gas supply pipe on gas burn-

ers.

Danger

Escaping gas leads to a risk of

explosion.

Check all gas connections for

tightness.

Tighten screws A crosswise

(torque 25 Nm).

Danger

Leaks can result in a risk of poi-

soning through escaping gas.

Check gaskets carefully.

Checking the function of the safety equipment

Check safety valves, water level and

pressure limiter in accordance with man-

ufacturer's details.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Checking the expansion vessel and system pressure

Documentation of the expansion

vessel manufacturer

Note

Carry out this test on a cold system.

Expansion vessel

1. Drain the system until the pressure

gauge indicates "0" or 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 + supplement).

The supplement is subject to the set-

tings of the high limit safety cut-out.

For a high limit safety cut-out setting

■ 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 pres-

sure 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 softened water*1 until the

charge pressure 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: 5 bar

(0.5 MPa)

*1 For water quality requirements, see page 22.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Pump controlled pressure maintaining systems

!Please note

Pressure fluctuations may cause

damage to the boiler or to other

system components.

In heating systems with auto-

matic pressure maintaining sys-

tems, and in particular pump con-

trolled systems with integral dea-

eration, we recommend the

installation of an expansion ves-

sel for individual boiler protec-

tion.

This reduces the frequency and

level of pressure fluctuations.

This contributes considerably to

improved operational reliability

and longer service life of the sys-

tem components.

Boiler

output

kW up to

300

up to

500

up to

1000

Expan-

sion ves-

sel

litre 50 80 140

!Please note

The ingress of oxygen can result

in system damage as a conse-

quence of oxygen corrosion.

Ensure that only pump controlled

pressure maintaining systems

that are sealed against corrosion

and protected against oxygen

ingress into the heating water are

used.

Pump controlled pressure main-

taining systems with atmospheric

deaeration through cyclical pres-

sure release create a central

post-venting of the heating sys-

tem. However, this does not rep-

resent oxygen removal in the

sense of corrosion protection

according to directive VDI 2035

sheet 2.

Carry out all checks in accordance with

the manufacturer's instructions. Limit

pressure fluctuations to the lowest pos-

sible differential. Cyclical pressure fluc-

tuations and more significant pressure

differentials point towards a system fault.

Immediately remedy such faults, other-

wise other heating system components

may become damaged.

Checking the water quality

Observe the instructions in chapter

"Water quality requirements".

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Enter the volume of top-up water and the

total hardness of the feed and boiler

water into the table.

Meter read-

ing

Fill and top-

up water

Total water

volume

Total hardness pH value Date

Feedwater Boiler wa-

ter

m3m3m3°dH °dH

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

Further details regarding the individual steps (cont.)

5692 701 GB

Cleaning the sight glass in the boiler door

Check the gaskets and hose connection

for leaks.

Checking the mixer for ease of operation and tightness

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-ring gaskets if the mixer is leak-

ing.

4. Snap the motorised lever into place.

Checking the Vitoair draught stabiliser (if installed)

Release the latch on the control disc. The control disc must swing freely during

burner operation.

Adjusting the burner

Burner service instructions or

separate documentation from the

burner manufacturer.

Adjust the maximum oil or gas through-

put of the burner to the rated boiler heat-

ing output.

Rated

heating

output

Pressure drop on the

hot gas side

kW Pa mbar

150 60 0.6

200 120 1.2

250 130 1.3

310 230 2.3

400 250 2.5

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Rated

heating

output

Pressure drop on the

hot gas side

kW Pa mbar

500 230 2.3

620 310 3.1

The minimum boiler water temperature

for oil and gas operation is 75 °C.

Safeguard the boiler return temperature

(minimum temperature) of 65 °C.

Set the minimum heating output for the

base load stage according to the condi-

tions of the flue system. Note that the flue

system must be suitable for the low flue

gas temperatures that may occur.

If the boiler frequently cycles in standby

mode and for partial loads below 40 %

we recommend thermally insulating the

flue gas collector, installing a motorised

flue gas damper and setting the mini-

mum boiler runtime to 10 minutes.

This extends the service life and reduces

the running costs.

Instructing the system user

The installer should instruct the user in

the operation of the system.

Operating and service documents

1. Complete and detach the customer

registration card:

■ Hand system users their section for

safekeeping.

■ Retain the heating contractor's

section.

2. File all parts lists, operating and serv-

ice instructions in the folder and hand

this over to the system user.

The installation instructions are no

longer required after the installation is

complete and therefore do not need

to be retained.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 701 GB

Spare parts information

Quote the part no. and serial no. (see

type plate) and the position number of

the required part (as per this parts list).

Standard parts are available from your

local supplier.

Parts

001 Boiler door

002 Bolts

003 Sight glass pack, comprising:

Pos. 004 to 008

004 Hose

005 Sight glass closure

006 Sight glass with pos. 007

007 Seal ring

008 Hose nozzle

009 Hose pack Ø 18 mm

010 Thermal insulation block

011 Thermal insulation mat

013 Packing 20 x 15 mm

014 Turbulator

015 Gasket

016 Cleaning cover

017 Packing 10 x 10 mm

018 Sensor well

200 Front panel, top

201 Back panel, top

202 Back panel, bottom

203 Side panel, back left

204 Side panel, front left and back right

205 Top panel, right

206 Top panel, left

207 Thermal insulation jacket

208 Thermal insulation mat, back

209 Vitoplex 100 logo

210 Control unit fascia

211 Edge protector

212 Side panel, front right with pos. 209

Parts not shown

300 Installation instructions

301 Service instructions

302 Thermal insulation pack

303 Spray paint, Vitosilver

304 Touch-up paint stick, Vitosilver

305 Flame tube gasket pack

Accessories

020 Brush handle

021 Extension piece

022 Turbulator extractor

Wearing part

019 Cleaning brush

AType plate, optionally left or right

BBoiler control unit, see parts list in

the service instructions of the boiler

control unit

CBurner cable, see parts list in the

service instructions of the boiler

control unit

Parts lists

(cont.)

5692 701 GB

011

021

019

013

009

001

008

007

005

002

006

004

010

206 205

022

020

008

200

210

211

Parts lists

(cont.)

5692 701 GB

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Viessmann Vitoplex 100 Service Instructions Manual

Brand: Viessmann

Model: Vitoplex 100

Category: Water heaters & boilers

Type: Service Instructions Manual

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Viessmann Vitoplex 100 Service Instructions Manual

Viessmann Vitoplex 100 Service Instructions Manual

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