Viessmann VITOPLEX 100 Mode d'emploi

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.

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

5692701

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

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

5692701

Symbol Meaning

Reference to other document containing

further information

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.

■Acoustic signal

■Fit new component.

■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

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

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

Note

On gas burners, disconnect the gas supply pipe.

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.

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

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°

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

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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