Viessmann VITOPLEX 100 Betriebsanleitung
Service instructions
for contractors
VIESMANN
Vitoplex 100
Type PV1, 150 to 620 kW
Oil/gas boiler
VITOPLEX 100
5692701 GB 1/2018 Please keep safe.
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.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
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
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■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.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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 func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5692701
3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never 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.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692701
4
1. Product information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Ordering parts ........................................................................................ 15
Parts ...................................................................................................... 16
Parts ...................................................................................................... 18
4. Water quality Water quality requirements .................................................................... 20
■Prevention of damage due to scaling ................................................. 20
■Prevention of damage due to corrosion on the water side ................. 21
Using antifreeze in boilers ..................................................................... 21
5. Commissioning/service
reports
Water quality .......................................................................................... 23
Maintenance/service .............................................................................. 23
6. Specification ................................................................................................................ 25
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 26
8. Certificates EU Declaration of Conformity ................................................................ 27
Manufacturer's certificate ....................................................................... 28
9. Keyword index ................................................................................................................ 29
Index
Index
5692701
5
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.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
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.
Product information
Symbols
5692701
Information
6
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 7
• • 2. Shutting down the system................................................................................................. 7
• • 3. Closing the Vitoair draught stabiliser (if installed)......................................................... 7
• • 4. Opening the boiler door and cleaning cover................................................................... 8
•5. Cleaning the turbulators, heating surface, flue outlet and flue pipe............................. 8
••• 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.................................................................................................... 9
• • 9. Securing the boiler door and cleaning cover.................................................................. 9
••• 10. Checking connections and sensor well on the heating water side for tightness
••• 11. Checking the function of the safety equipment.............................................................. 10
••• 12. Checking the expansion vessel and system pressure................................................... 10
••• 13. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 11
••• 14. Checking electrical plug-in connections and cable grommets for firm seating
••• 15. Checking the thermal insulation
• • 16. Checking the water quality................................................................................................ 12
• • 17. Cleaning the sight glass in the boiler door...................................................................... 12
••• 18. Checking the mixer for ease of operation and tightness............................................... 12
••• 19. Checking the function of the return temperature raising facility (if installed)
••• 20. Checking the installation room ventilation
••• 21. Checking the flue pipe for leaks
••• 22. Checking the Vitoair draught stabiliser (if installed)...................................................... 13
• • 23. Adjusting the burner.......................................................................................................... 13
•24. Instructing the system user.............................................................................................. 13
•25. Operating and service documents................................................................................... 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692701
7
Operating and service instructions for the control
unit and the burner
01. Check that the turbulators are fully inserted into
the hot gas flues (see page 9); open the boiler
door for this.
02. Check that the ventilation air aperture in the instal-
lation room 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 softened
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 the appendix; see page 23.
05. Check the system pressure.
06. Check the oil level or the gas supply pressure.
07. Open the flue gas damper (if installed).
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 that order. Observe the burner manufac-
turer’s operating instructions.
11. The dew point range must be cleared as quickly
as possible. To do so, prevent any heat supply to
the consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
!Please note
During boiler heat-up, unpleasant fumes
and odours can result from outgassing from
the thermal insulation, the thermal block and
the paint.
Ventilate the room during commissioning.
12. Once the flow temperature has been reached,
successively switch on the heat consumers.
Switch the burner over to automatic mode.
!Please note
When checking CO levels in the flue gas,
internal outgassing from the thermal block
can result in higher values.
Continue to operate the boiler until a decline
can be clearly recognised.
13. Check all gaskets and plugs, and retighten if nec-
essary.
14. Check the boiler door and cleaning cover after
approx. 50 hours run. Tighten the screws.
Danger
Opening the connections on the heating water
side whilst the boiler is under pressure can
result in injuries.
First depressurise the boiler.
Only drain the boiler with a suction pump when
the air vent valve is open.
Shutting down the system
Danger
The connections on the heating water side must
only be opened after the boiler has been dep-
ressurised.
Only drain the boiler with a suction pump when
the air vent valve is open.
Closing the Vitoair draught stabiliser (if installed)
1. Start the burner. 2. When pre-purge is active, switch off the system;
the control disc is then closed.
Commissioning, inspection, maintenance
Commissioning the system
5692701
8
Note
On gas burners, disconnect the gas supply pipe.
4x
Fig. 1
Cleaning the turbulators, heating surface, flue outlet and flue pipe
CBA
Fig. 2
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.
D
Fig. 3
3. Use a vacuum cleaner to remove combustion resi-
dues from the flue and the flue outlet through
cleaning aperture D in the flue outlet.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover
5692701
9
Checking the thermal insulation components on the boiler door
Inserting the turbulators
!Please note
Burner adjustments and specific system condi-
tions can cause the turbulators to move forward,
which may result in them being burnt. This can
also lead to damage to the thermal insulation on
the boiler door.
Before insertion, the turbulators must be slightly
bent (see steps).
10-15°
B
A
Fig. 4
1. Push turbulators A approx. ¼ of their length into
hot gas flues B.
2. Bend turbulators approx. 10 to 15°.
3. Push the turbulators into the hot gas flues as far as
they will go. When doing this, check the pre-stress-
ing.
Note
Ensure that the turbulators cannot easily be pulled
out of the hot gas flues.
Securing the boiler door and cleaning cover
Note
On gas burners, mount the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for leaks.
Commissioning, inspection, maintenance
Checking all gaskets and packing cords on the flue gas side
5692701
10
4x
A
Fig. 5
Tighten screws A crosswise (torque 25 Nm).
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
Checking connections and sensor well on the heating water side for tight-
ness
Checking the function of the safety equipment
Check the safety valves, water level and pressure lim-
iter in accordance with manufacturer's instructions.
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation Note
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Securing the boiler door and cleaning cover (cont.)
5692701
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4
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