Viessmann Vitoplex 100 PV1 Bedienungsanleitung

Installation instructions

for contractors

VIESMANN

Vitoplex 100

Type PV1, 150 to 620 kW

Oil/gas boiler

VITOPLEX 100

5592 753 GB 10/2014 Dispose after installation.

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 must only be carried out by

a registered gas fitter.

■Work on electrical equipment must only be carried

out by a qualified electrician.

Regulations

Observe the following when working on this system:

■Statutory regulations regarding the prevention of

accidents

■Statutory regulations regarding environmental pro-

tection

■The Code of Practice of relevant trade associations

■all current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE [and all local standards].

aÖNORM, EN, ÖVGW-TR Gas, 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

5592 753 GB

1. Information Symbols ................................................................................................. 4

Intended use .......................................................................................... 4

Clearance dimensions ........................................................................... 4

2. Installation sequence Siting and levelling the boiler ................................................................. 6

Changing the boiler door opening ......................................................... 6

Connections on the heating water side .................................................. 6

Making the safety connection and testing for tightness ......................... 7

Making connections on the flue gas side ............................................... 8

Fitting the thermal insulation .................................................................. 8

■Boiler body thermal insulation ............................................................ 8

■Rear thermal insulation ....................................................................... 9

■Side panels and burner cables ........................................................... 10

■Front panel ......................................................................................... 11

■Rear panels ........................................................................................ 11

■Preparing for the control unit installation ............................................ 12

■Routing cables .................................................................................... 12

■Top panels and type plate ................................................................... 13

■Control unit fascia ............................................................................... 14

Mounting the burner ............................................................................... 14

Mounting the combustion chamber sight glass ...................................... 14

Commissioning and adjustment ............................................................. 14

3. Specification

Index

5592 753 GB

Symbol Meaning

Reference to other document containing

further information

Additional information, not safety relevant

Step:

The numbering corresponds to the se-

quence of work.

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.

Clearance dimensions

(300)

200 (100)

500 (50)

400 a

500 (50)

Fig. 1

ABoiler

BBurner

CAnti-vibration boiler supports (accessories)

Dimensions in brackets are minimum clearances.

Symbols

5592 753 GB

Rated heating output kW 150 200 250 310 400 410 500 620 500

a*1 mm 1100 1250 1500

bmm Observe the installed burner length.

Fig. 2

CAnti-vibration boiler support (accessory)

Rated heating output kW 150 200 250 310 400 410 500 620

Anti-vibration boiler supports

Permissible load kg 1500 2700 3336

c (front) / number mm/pce 375/2 334/2 500/2

c (back) / number mm/pce 375/2 334/2 334/2

d mm 30 100 100

e (unstressed) mm 42

e (stressed) mm 37

*1 Maintain this space in front of the boiler to enable the removal of the turbulators or for cleaning the hot gas flues.

Clearance dimensions (cont.)

5592 753 GB

Fig. 3

Level the boiler horizontally. No special foundations

are required.

Note

We recommend siting the boiler on anti-vibration

boiler supports C (see chapter "Clearance dimen-

sions").

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 3 x timbers

(□ 35 mm).

Changing the boiler door opening

Fig. 4

Note

The boiler door is hung on the opposite side by moving

bolt A to the r.h. side. Sealing frame B should press

centrally onto boiler door gasket D when the boiler

door is closed. If necessary, align mounting bracket

Connections on the heating water side

Danger

Opening the connections on the heating water

side whilst the boiler is under pressure can

result in injuries.

First depressurise the boiler.

Note

Install all pipe connections free of load and torque

stress.

Siting and levelling the boiler

5592 753 GB

ABCD

Fig. 5

ABoiler return

for 150 to 310 kW: DN 65

for 400 to 620 kW: DN 100

BSafety connection (safety valve), see page 7

CBoiler flow

for 150 to 310 kW: DN 65

for 400 to 620 kW: DN 100

DFemale connection for boiler water temperature

sensor, high limit safety cut-out and temperature

controller

EDrain, R 1¼

Making the safety connection and testing for tightness

Install the safety lines.

Safety connection

150 to 310 kW R 1¼

400 to 620 kW R 1½

Permiss. operating pressure 5 bar (0.5 MPa)

Test pressure 6.5 bar (0.65 MPa)

Low water indicator

According to EN 12828, a low water indicator can be

omitted for Vitoplex 100 boilers up to 300 kW (except

in attic heating centres), as the standard boiler control

unit prevents impermissible heating.

If required, install a low water indicator or a minimum

pressure limiter into the pipework.

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.

!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).

Connections on the heating water side (cont.)

5592 753 GB

Ø D Ø 10

2-3 x Ø D

Fig. 6

Vitoair installation instructions

1. Connect the flue outlet with the shortest possible

run to the chimney and maintain a slight incline.

External Ø, flue outlet:

150 and 200 kW: 178 mm

250 and 310 kW: 198 mm

400 to 620 kW: 248 mm

2. Create a test port.

3. Seal in and insulate the flue pipe. 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.

Boiler body thermal insulation

B A

Fig. 7

ABlack side outwards

Making connections on the flue gas side

5592 753 GB

Note

Remove bag B containing the type plate and keep

safe. This will be required later.

Rear thermal insulation

Fig. 8

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.)

5592 753 GB

Side panels and burner cables

3.9 x 9.5

lÖ

Fig. 9

ASide panel, front right

BVitoplex 100 logo

Note

Provide burner cables on site if they are not supplied.

The inclusion of burner cables in the standard delivery

depends on which control unit is being supplied.

Note

Route the burner cables fA and lÖ along the side of

the boiler where the boiler door hinges are located.

Fitting the thermal insulation (cont.)

5592 753 GB

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