Viessmann VITOPLEX 200 Betriebsanleitung

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

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.)

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

5692 727 GB

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

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



••• 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

Commissioning, inspection, maintenance

5692 727 GB

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•21. Operating and service documents ................................. 16

Steps –commissioning, inspection and . . . (cont.)

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

ATurbulator extractor

3. Check that the installation room

ventilation aperture is open.

Further details regarding the individual steps

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

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.)

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.)

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.)

Commissioning, inspection, maintenance

5692 727 GB

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