for contractors Service instructions Type SX2A , 90 to 560 ... · Service instructions for contractors Vitoplex 200 VIESMANN Type SX2A, 90 to 560 kW Oil/gas boiler For applicability,

Service instructionsfor contractors

VIESMANN

Vitoplex 200Type SX2A, 90 to 560 kWOil/gas boiler

For applicability, see the last page

VITOPLEX 200

5692 848 GB 3/2013 Please keep safe.

2

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

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Please noteThis symbol warns against therisk of material losses and envi-ronmental pollution.

NoteDetails 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 bythe system installer or a qualified per-son authorised by the installer.

Regulations

Observe the following when working onthis 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 asdefined by DIN, EN, DVGW, TRGI,TRF, VDE and all locally applicablestandards

■ Gas Safety (Installation & Use) Regu-lations– the appropriate Building Regulationeither the Building regulations, theBuilding Regulation (Scotland), Build-ing Regulations (Northern Ireland),– the Water Fittings Regulation orWater Bylaws in Scotland,– the current I.E.E. Wiring Regula-tions.

If you smell gas

DangerEscaping gas can lead to explo-sions which may result in seriousinjury.■ Do not smoke. Prevent naked

flames and sparks. Do notswitch 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 thebuilding.

■ Shut off the electricity supply tothe building from a safe place(outside the building).

Safety instructions

Safety instructions

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If you smell flue gas

DangerFlue 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 andcannot be sealed, for instance due toaccumulation of condensate or othercauses. Ensure a sufficient supply ofcombustion air.Instruct system users that subsequentmodifications to the building characteris-tics are not permissible (e.g. cable/pipe-work routing, cladding or partitions).

DangerLife-threatening poisoningcaused by carbon monoxide inthe flue gas occurs as a result ofleaking or blocked flue systemsor an insufficient supply of com-bustion air.Ensure the flue system is inproper working order. It must notbe possible to close apertures forinterconnected combustion airsupply.

Extractors

Operating appliances that extract air tothe outside (cooker hoods, extractors, airconditioning units, etc.) can create neg-ative pressure. If the boiler is operated atthe same time, this can lead to reverseflow of the flue gas.

DangerThe simultaneous operation ofthe boiler and appliances thatextract air to the outside canresult in life threatening poison-ing due to reverse flow of the fluegas.Fit an interlock circuit or take suit-able steps to ensure a sufficientsupply of combustion air.

Working on the system

■ Where gas is used as the fuel, closethe 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 fuseor by means of a mains isolator) andcheck that it is no longer 'live'.

■ Safeguard the system against recon-nection.

! Please noteElectronic assemblies can bedamaged by electrostatic dis-charge.Prior to commencing any work,touch earthed objects, such asheating or water pipes to dis-charge static loads.

Repair work

! Please noteRepairing components that fulfil asafety function can compromisethe safe operation of your sys-tem.Defective components must bereplaced with genuineViessmann spare parts.

Safety instructions

Safety instructions (cont.)

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Auxiliary components, spare andwearing parts

! Please noteSpare and wearing parts thathave not been tested togetherwith the system can compromiseits function. Installing non-author-ised components and makingnon-approved modifications orconversions can compromisesafety and may invalidate ourwarranty.For replacements, use only orig-inal spare parts supplied orapproved by Viessmann.

Safety instructions

Safety instructions (cont.)

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Product informationIntended use......................................................................................................... 6

Commissioning, inspection, maintenanceSteps - commissioning, inspection and maintenance.......................................... 7Further details regarding the individual steps....................................................... 9

Parts lists............................................................................................................ 21

Water qualityWater quality requirements.................................................................................. 24Using antifreeze in boilers.................................................................................... 27

Commissioning/service reports........................................................................ 29

Specification....................................................................................................... 30

CertificatesDeclaration of conformity...................................................................................... 31Manufacturer's certificate according to the 1st BImSchV [Germany]................... 32

Keyword index.................................................................................................... 33

Index

Index56

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The appliance is only intended to beinstalled and operated in sealed unven-ted heating systems that comply withEN 12828, with due attention paid to theassociated installation, service andoperating instructions as well as thedetails in the datasheet.It is only designed for the heating up ofheating water.

Commercial or industrial usage for a pur-pose other than the heating up of heatingwater shall be deemed inappropriate.

Intended use presupposes that a fixedinstallation in conjunction with permissi-ble components designed for this pur-pose has been carried out.Every other use will be deemed to beinappropriate. Any resulting losses areexcluded from the manufacturer's liabil-ity.

Any usage beyond this must beapproved by the manufacturer for theindividual case.

Intended use also includes the adher-ence to maintenance and inspectionintervals.

Product information

Intended use

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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 outletand flue pipe.................................................................... 12

• • • 6. Checking all gaskets and packing cords on the fluegas side

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

• 8. Inserting the turbulators................................................ 13

• • 9. Securing the boiler door and cleaning cover............... 14

• • • 10. Checking connections and sensor well for leaks onthe heating water side

• • • 11. Checking the function of the safety equipment........... 15

• • • 12. Checking the expansion vessel and system pressure 15

• • • 13. Checking the firm seating of electrical plug-inconnections and cable grommets

• • • 14. Checking the thermal insulation

• • 15. Checking the water quality............................................ 16

• • 16. Cleaning the sight glass in the boiler door.................. 18

• • • 17. Checking the mixer for ease of operation andtightness.......................................................................... 18

• • • 18. Checking the function of the return temperatureraising facility (if installed)

• • • 19. Checking the installation room ventilation

• • • 20. Checking the flue pipe for tightness

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance56

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Commissioning steps

Inspection steps

Maintenance steps Page

• • 21. Checking the Vitoair draught stabiliser (if installed)... 18

• • 22. Adjusting the burner...................................................... 18

• 23. Instructing the system user........................................... 20

• 24. Operating and service documents................................ 20


Steps - commissioning, inspection and… (cont.)

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Commissioning the system

Operating and service instruc-tions for the control unit and theburner

01. Check that the turbulators are fullyinserted into the hot gas flues (seepage 13); open the boiler door forthis.

02. Check that the installation roomvent is open.

03. Fill the heating system with waterand vent the system.Permissible operating pressure:4 bar (0.4 MPa)

! Please noteScaling and boiler damagemay result if the system isnot operated with fully soft-ened heating water.Operate boilers only withsoftened water.Observe the instructions inchapter "Water qualityrequirements".

04. Enter the amount of fill water andwater hardness into the table inchapter "Checking the water qual-ity".

05. Check the system pressure.

06. Check the oil level or the gas supplypressure.

07. Open the flue gas damper (if instal-led).

08. Check that the cleaning aperture onthe flue outlet is closed.

09. Open the shut-off valves in the oil orgas line.

10. Switch ON the mains isolator, theswitch for the heating circuit pumpand the burner ON/OFF switch inthis order (observe the burner man-ufacturer's instructions).

11. When heating the system from cold(also when restarting after mainte-nance and cleaning work), preventall heat supply to heat consumers,to clear the dew point range asquickly as possible.

! Please noteDuring boiler heat-up,unpleasant fumes andodours can result from out-gassing from the thermalinsulation, the thermal blockand the paint.Vent the room during com-missioning.


Further details regarding the individual steps56

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12. After the flow temperature has beenreached, switch ON the heat con-sumers in sequence and change theburner over to automatic mode.

! Please noteWhen testing the flue gas forCO, internal gases beingexpelled from the thermalblock can result in higher val-ues.Continue to operate theboiler until a decline can beclearly recognised.

13. Check all gaskets and plugs, andretighten if necessary.

14. Check the boiler door and cleaningcover after approx. 50 hours run andretighten all screws.

Shutting down the system

DangerOpening the connections on theheating water side whilst theboiler is under pressure canresult in injuries.First depressurise the boiler.Only drain the boiler with a suc-tion pump when the air vent valveis open.

Closing the Vitoair draught stabiliser (if installed)

1. Start the burner. 2. With pre-purge active, shut down thesystem. The control disc will then beclosed.

Opening the boiler door and cleaning cover

NoteOn gas burners, disconnect the gas sup-ply pipe.


Further details regarding the individual steps (cont.)

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4x



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Cleaning the turbulators, heating surface, flue outlet and fluepipe

BCA

1. Remove turbulators A withoutapplying force.

2. Clean flues B and combustionchamber C with the brush.Remove combustion residues with avacuum cleaner.

3. Remove combustion residues fromthe flue and the flue outlet through thecleaning aperture in flue outlet Dusing a vacuum cleaner.



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Inserting the turbulators

! Please noteBurner adjustments and specificsystem conditions can cause theturbulators to move forward,which may result in them beingburnt. This can also lead to dam-age to the thermal insulation onthe boiler door.

Before insertion, the turbulatorsmust be slightly bent (seesteps).

BA

10-15°

1. Push turbulators A approx. ¼ oftheir length into hot gas flues B.

2. Bend turbulators approx. 10 - 15°.

3. Push the turbulators into the hot gasflues as far as they will go. Whendoing this, check the pre-stressing.

NoteEnsure that turbulators cannot easilybe pulled out of the hot gas flues.



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Securing the boiler door and cleaning cover

NoteMount the gas supply pipe on the gasburner.

DangerEscaping gas leads to a risk ofexplosion.

Check all gas connections fortightness.

4x

A

Tighten screws A crosswise (tor-que 25 Nm).

DangerLeaks can result in a risk of poi-soning through escaping gas.Check gaskets carefully.



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Checking the function of the safety equipment

Check safety valves, water level andpressure limiter in accordance with man-ufacturer's details.

Checking the expansion vessel and system pressure

Expansion vessel manufacturer'sdocumentation

NoteCarry out this test on a cold system.

Expansion vessel

1. Drain the system until the pressuregauge indicates "0" or close the capvalve on the expansion vessel anddepressurise the expansion vessel.

NoteThe pre-charge pressure of theexpansion vessel (p0) is made up ofthe 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 settingof■ 100 °C: it is 0.2 bar (0.02 MPa)■ 110 °C: it is 0.7 bar (0.07 MPa).

2. If the pre-charge pressure of theexpansion vessel is lower than thestatic system pressure, top up withnitrogen until the pre-charge pres-sure is 0.1 to 0.2 bar (0.01 to0.02 MPa) higher. The static pressure corresponds tothe static head.

3. Top up with softened water*1 until thecharge pressure of the cooled systemis 0.1 to 0.2 bar (0.01 to 0.02 MPa)higher than the pre-charge pressureof the expansion vessel. Permiss. operating pressure: 4 bar(0.4 MPa)

*1 For water quality requirements, see page 24.



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Pump-controlled pressure maintaining systems

! Please notePressure fluctuations may causedamage to the boiler or to othersystem components.In heating systems with auto-matic pressure maintaining sys-tems, and in particular pump-controlled systems with integraldeaeration, we recommend theinstallation of an expansion ves-sel for individual boiler protec-tion.This reduces the frequency andlevel of pressure fluctuations.This contributes considerably toimproved operational reliabilityand longer service life of the sys-tem components.

Boileroutput

kW up to300

up to500

up to1000

Expan-sion ves-sel

litre 50 80 140

! Please noteThe ingress of oxygen can resultin system damage as a conse-quence of oxygen corrosion.Ensure that only pump-controlledpressure maintaining systemsthat are sealed against corrosionand protected against oxygeningress into the heating water areused.Pump-controlled pressure main-taining systems with atmosphericdeaeration through cyclical pres-sure release achieve some cen-tral post-ventilation of the heatingsystem. However, this does notrepresent oxygen removal in thesense of corrosion protectionaccording to VDI 2035 sheet 2.

Carry out all checks in accordance withthe manufacturer's instructions. Limitpressure fluctuations to the lowest pos-sible differential. Cyclical pressure fluc-tuations and more significant pressuredifferentials point towards a system fault.Immediately remedy such faults, other-wise other heating system componentsmay become damaged.

Checking the water quality

Observe the instructions in chapter "Water quality requirements".



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Enter the amount of top-up water and the total hardness of the feed and boiler waterinto the table.

Meter read-ing

Fill and top-up water

Total watervolume

Total hardness pH value DateFeedwater Boiler wa-

term3 m3 m3 °dH °dH

The total hardness of the feed and top-up water must not exceed 0.11 °dH (total valueof alkaline earths ≤ 0.02 mol/m3). The pH value should be between 9 and 10.5.



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Cleaning the sight glass in the boiler door

Check the gaskets and hose connectionfor leaks.

Checking the mixer for ease of operation and tightness

1. Remove the motorised lever from themixer handle.

2. Check the mixer for ease of opera-tion.

3. Check the mixer for tightness.Replace the O-ring gaskets if themixer is leaking.

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 duringburner operation.

Adjusting the burner

Burner service instructions orseparate documentation from theburner manufacturer.

Adjust the maximum oil or gas through-put of the burner to the rated boiler heat-ing output.



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Ratedheatingoutput

Pressure drop on thehot gas side

kW Pa mbar90 60 0.6

120 80 0.8150 100 1.0200 200 2.0270 180 1.8350 310 3.1440 280 2.8560 400 4.0

To protect the system against dew pointcorrosion, burner stage 2 (full heatingoutput) must be set to the rated boilerheating output and must not be switchedoff during summertime (burner stage 2on constant standby).

Partial load operation

Set the minimum heating output for thebase load stage according to the condi-tions of the flue system. Note that the fluesystem must be suitable for the low fluegas temperatures that may occur.If the boiler frequently cycles in standbymode and for partial loads below 40 %we recommend thermally insulating theflue gas collector, installing a motorisedflue gas damper and setting the mini-mum boiler runtime to 10 minutes.This extends the service life and reducesrunning costs.

Operation with burner load ≥ 60 %

The minimum boiler water temperaturefor oil operation is 50 °C and for gasoperation 60 °C.

To protect the boiler, the minimum heat-ing output at the base load stage is setto 60 % of rated heating output.

Rated heatingoutput

Minimum heatingoutput to be set(burner stage 1)

kW kW90 54

120 72150 90200 120270 162350 210440 264560 336

A minimum flue gas temperature isrequired for the base load stage, thevalue of which is subject to the design ofthe flue system.

Operation with burner load ≥ 40 % and< 60 %

For oil operation, the minimum systemtemperatures (flow/return) are 60/50 °Cand for gas operation 70/60 °C.

Operation with burner load < 40 %

For oil operation, the minimum systemtemperatures (flow/return) are 60/55 °Cand for gas operation 70/65 °C.



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Instructing the system user

The installer should instruct the user inthe operation of the system.

Operating and service documents

1. Complete and detach the customerregistration 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 handthis over to the system user.The installation instructions are nolonger required after the installation iscomplete and therefore do not needto be retained.



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Spare parts informationQuote the part no. and serial no. (seetype plate) and the position number ofthe required part (as per this parts list).Standard parts are available from yourlocal supplier.

Parts001 Boiler door002 Studs003 Sight glass pack, comprising:

pos. 004 to 007004 Sight glass frame pack005 Gasket006 Hose nozzle007 Plastic hose008 Hose pack Ø 18 mm009 Thermal insulation block010 Thermal insulation mat012 Packing GF 20 x 15 mm013 Turbulator014 Gasket015 Cleaning cover016 Packing017 Sensor well, boiler water tempera-

ture sensor018 Sensor well, ThermControl200 Front panel, top201 Front panel, bottom202 Back panel, top203 Back panel, bottom204 Side panel, front right (with pos.

212)205 Side panel, front left206 Top panel, right207 Top panel, left208 Control unit fascia209 Thermal insulation jacket

210 Thermal insulation mat, back211 Thermal insulation mat, flue gas

collector212 Vitoplex 200 logo213 Edge protector214 Fixing rail, top215 Fixing rail, bottom216 Side panel, centre (only from

440 kW)217 Side panel, back right218 Side panel, back left

Parts not shown300 Installation instructions301 Service instructions302 Thermal insulation pack303 Touch-up spray paint, Vitosilver304 Touch-up paint stick, Vitosilver305 Blast tube gasket pack

Wearing part019 Cleaning brush

Accessories020 Brush handle021 Extension piece022 Burner plate pack*2

023 Burner plate gasket*2

A Type plate, optionally left or rightB Boiler control unit, see parts list in

the service instructions of the boilercontrol unit

C Burner cable, see parts list in theservice instructions of the boilercontrol unit

D ThermControl temperature sensor

*2 from 150 kW

Parts lists

(cont.)

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012

008

009

200

208

207 206

B

019

021

020

001002010

214214

022 023

003

005004006007

Parts lists

(cont.)

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218204

209

C

C

203

213

213

211

217205

014

014

013

210

202

016

015

017

D

018

201215 215

216

216

A

19 24 26 32NumberkW 90 120 150 200 270 350 440

191414Rated heating outputInformation on position 013

38560

212

Parts lists

(cont.)

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NoteObserving the following requirements is necessary to safeguard your warrantyrights.The warranty excludes damage due to corrosion and scaling.

Prevention of damage due to scaling

Prevent excessive scale build-up (calcium carbonate) on the heating surfaces. Forheating systems with operating temperatures up to 100 °C, guideline VDI 2035 sheet1 "Prevention of damage in water heating installations - Scale formation in domestichot water supply installations and water heating installations" applies [in Germany],with the following standard values (see also the full explanations in the original).

Total heating outputkW

Total alkaline earthsmol/m3

Total hardness°dH

> 50 to ≤ 200 ≤ 2.0 ≤ 11.2> 200 to ≤ 600 ≤ 1.5 ≤ 8.4> 600 < 0.02 < 0.11

The standard values assume the follow-ing:■ The total volume of fill and top-up

water will not exceed three times thewater content of the heating systemduring its service life.

■ The specific system volume is lessthan 20 l/kW heating output. In multiboiler systems, apply the output of thesmallest boiler.

■ All measures to prevent corrosion onthe water side in accordance withVDI 2035 Part 2 have been implemen-ted.

Soften the fill and top-up water in heatingsystems operating under the followingconditions:■ The total of alkaline earths in the fill

and top-up water exceeds the stand-ard value.

■ Higher fill and top-up water volumesare expected.

■ The specific system volume is greaterthan 20 l/kW heating output. In multiboiler systems, apply the output of thesmallest boiler.

Water quality

Water quality requirements

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■ In systems > 50 kW, install a watermeter to record the volume of the filland top-up water. Enter the volume offill water and the water hardness intothe boiler maintenance checklists.

■ For systems with a specific system vol-ume in excess of 20 l/kW heating out-put (in multi boiler systems apply theoutput of the smallest boiler), apply therequirements of the next higher cate-gory of total output (in accordance withthe table). In the case of severeexcess (> 50 l/kW), soften the waterdown to a total of alkaline earths of≤ 0.02 mol/m3.

Operating information:■ During expansion or repair work, only

drain the necessary pipework sec-tions.

■ Check, clean and activate filters, dirttraps and other blow-down or separat-ing facilities in the heating water circuitmore frequently after commissioningor new installations; later on do so sub-ject to requirements in line with thewater treatment applied (e.g. watersoftening).

■ No further steps are required duringcommissioning if you fill the heatingsystem with fully softened water.If the heating system is not filled withfully softened water, but with waterthat meets the requirements in theabove table, also observe the follow-ing during commissioning:

■ Commission the system step by step,starting with the lowest boiler outputand a high heating water flow rate.This prevents a localised concentra-tion of limescale deposits on the boilerheating surfaces.

■ In multi boiler systems, start all boilerssimultaneously to prevent the entirelimescale deposit settling in the heattransfer area of just one boiler.

■ Where water treatment is required,treat even the first fill of the heatingsystem prior to commissioning. Thisalso applies to any subsequent filling,e.g. after repairs or after systemexpansion, and for any top-up water.

The build-up of limescale deposits on theheating surfaces will be minimised ifthese instructions are observed.If limescale deposits have formedbecause of a failure to observe therequirements of guideline VDI 2035 theservice life of the installed heating appli-ances will, in most cases, already havebeen reduced.Removing the limescale deposits is oneoption for restoring operational viability.This measure must be carried out by aspecialist. Inspect the heating system forpossible damage prior to returning it intouse.It is essential that the faulty operatingparameters are corrected to preventrenewed formation of excessive scaledeposits.

Water quality

Water quality requirements (cont.)

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Prevention of damage due to corrosion on the water side

The corrosion resistance of ferrousmaterials on the heating water side ofheating systems and heat generatorsdepends on the absence of oxygen in theheating water. The oxygen introducedinto the heating system with the first filland subsequent top-ups reacts with thesystem materials without causing dam-age.The characteristic blackening of thewater after a certain time in operationindicates that there is no more free oxy-gen present. The technical rules and inparticular guideline VDI 2035-2 thereforerecommend that heating systems aredesigned and operated so that a con-stant ingress of oxygen into the heatingwater is prevented.During operation, oxygen can normallyonly enter due to:■ Open expansion vessels receiving a

flow■ Negative pressure in the system■ Gas-permeable componentsSealed unvented systems – e.g. thoseequipped with an expansion vessel –offer good protection against the ingressof airborne oxygen into the system, ifcorrectly sized and operating at the cor-rect pressure.In all operating states and at all points inthe heating system, including the intakeside of the pump, the pressure must behigher than the surrounding atmosphericpressure. The pre-charge pressure ofthe expansion vessel should be checkedat least during the annual service. Forpressure maintaining systems, seepage 16.

The use of permeable components, e.g.permeable plastic pipes in underfloorheating systems, should be avoided.Provide system separation if such com-ponents are nevertheless used. Thismust separate the water flowing throughthe plastic pipes from other heating cir-cuits – e.g. from the boiler – by the pro-vision of a corrosion-resistant heatexchanger.No further anti-corrosion measures arerequired for sealed hot water heatingsystems, subject to the above pointsbeing observed. However, take addi-tional precautions where there is a risk ofoxygen ingress, for example by addingoxygen binder sodium sulphite (5 -10 mg/l into the excess). The pH value ofthe heating water should be between 9and 10.5.Different conditions apply to systemsthat contain aluminium components.Where chemicals are used as part of thecorrosion protection, we recommendthat the manufacturer of the chemicalsissues a certificate of suitability of theadditives with regard to the boiler mate-rials and the materials of the other heat-ing system components. We recom-mend you refer questions regardingwater treatment to an appropriate spe-cialist. For further details, see guidelineVDI 2035-2 and directive EN 14868.

Water quality

Water quality requirements (cont.)

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Viessmann boilers are designed andbuilt for water as a heat transfer medium.To protect boiler systems from frost, itmay be necessary to treat the boilerwater or circulating water with anti-freeze.

When doing so, observe the following:■ In general, follow the specifications

given by the antifreeze manufacturer.■ The properties of antifreeze and water

are very different.■ The temperature stability of the anti-

freeze must be sufficient for the par-ticular application.

■ Check the compatibility with sealingmaterials. If other sealing materialsare used, take this into account whendesigning the system.

■ Antifreeze developed especially forheating systems contains inhibitorsand buffer substances for corrosionprotection as well as glycol. Whenusing antifreeze, always observe themanufacturer's instructions regardingminimum and maximum concentra-tions.

■ The concentration must never fallbelow the prescribed minimum level,subject to the required frost protectiontemperature. Check and adjust the pHvalue and frost protection (measurethe density) regularly, at least once ayear, according to the manufacturer'sinstructions.

■ Check with the relevant supplierwhether antifreeze may affect systemcomponents that are not part of theboiler, such as pumps, electrically andpneumatically driven valves, othertypes of valves, gaskets, etc.

■ If the system is filled with antifreeze, itmust be marked accordingly.

■ If a boiler system is changed to oper-ate without antifreeze, flush the sys-tem in order to remove all traces of theantifreeze.

■ The quality of the boiler water andfeedwater must meet the require-ments of Directive VDI 2035.

■ The systems must be designed assealed unvented systems, as the anti-freeze inhibitors decrease rapidly if air-borne oxygen is allowed to enter.

■ Diaphragm expansion vessels mustcomply with DIN 4807 [or local regula-tions].

■ Solder connections should preferablybe made with Ag or Cu hard solder. Ifliquids containing chlorides are usedfor soft soldering, any deposits mustbe removed from the circuit afterwardsthrough thorough flushing. A higherchloride content in the heat transfermedium can cause corrosion damage.

■ Only use oxygen diffusion-resistanthoses or metal hoses for flexible con-nections.

■ Never equip the system on the primaryside with zinc-plated heat exchangers,containers or pipes as zinc can be cor-roded by glycol/water mixtures.

■ To avoid the risk of corrosion, ensurethat there is no difference in electricalpotential between system compo-nents that are in contact with anti-freeze.

■ Route all pipes in such a way that cir-culation cannot be interrupted by gascushions or deposits.

■ The water circuit must always be filledup to the highest point with the heattransfer medium.

Water quality

Using antifreeze in boilers56

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■ After filling, ensure there are no moreair cushions in the system. When thetemperature falls, gas cushions formnegative pressure and this can drawair into the system.

■ After initial filling and commissioning,but after 14 days at the latest, cleanthe integral dirt trap so the heat trans-fer medium can flow freely.

■ Following any losses through leaks ordrawing off, top up the antifreeze sol-ution according to the concentrationalready in place. Establish the volumeof antifreeze as a check.

Water quality

Using antifreeze in boilers (cont.)

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Commissioning Service Service date: by:

Service Service Service date: by:




Commissioning/service reports

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Rated heating output kW 90 120 150 200 270 350 440 560Flue gas parameters*3 Temperature at boilerwater temp. 60 °C

■ At rated heating output °C 180■ At partial load (60 %) °C 125Temperature at boilerwater temp. 80 °C

°C 195

Product ID CE-0085BQ0020Product parameters (according to EnEV)Efficiency η at ■ 100 % of the rated

heating output(80/60 °C)

% 91.9 92.0 92.0 92.0 92.1 92.2 92.2 92.3

■ 30 % of the rated heat-ing output (65/55 °C)

% 95.4 95.9 95.9 96.1 96.2 96.4 96.4 96.5

Standby loss qB,70 % 0.40 0.35 0.30 0.30 0.25 0.25 0.22 0.20Power consumption*4

at

■ 100 % of rated heatingoutput

W 359 420 455 529 578 744 — —

■ 30 % of rated heatingoutput

W 123 140 155 175 225 240 — —

*3 Values for sizing the flue system to EN 13384 relative to 13 % CO2 for fuel oil ELand 10 % CO2 for natural gas.

*4 Standard parameter.

Specification

Specification

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We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon-sible body, that the following product complies with the standards specified:

Vitoplex 200, type SX2A, 90 to 560 kW■ with the Vitotronic boiler control unit and■ with the Vitotronic boiler control unit and the Vitoflame pressure-jet burner

EN 226 EN 55014-2EN 267 EN 60335-1EN 303 EN 60335-2-102EN 676 EN 61000-3-2EN 14394 EN 61000-3-3 EN 50090-2-2 EN 62233EN 55014-1 TRD regulations

In accordance with the following Directives, this product is designated _-0085:

92/42/EEC 2006/95/EC2004/108/EC 2009/142/EC2006/42/EC

This product meets the requirements of the Efficiency Directive (92/42/EEC) for lowtemperature boilers (boilers < 400 kW).

The product characteristics determined as system values for the productVitoplex 200 as part of EC type testing according to the Efficiency Directive (seespecification table), can be utilised to assess the energy consumption of heating andventilation equipment to DIN V 4701-10, which is specified by the EnEV [Ger-many].

Allendorf, 22 February 2013 Viessmann Werke GmbH&Co KG

Authorised signatory Manfred Sommer

Certificates

Declaration of conformity56

92 8

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We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm that the productVitoplex 200, type SX2A, 90 to 560 kW complies with the following conditions stipu-lated by the 1st German Immissions Order (BImSchV):■ NOx limits in accordance with paragraph 6 (1).■ Flue gas loss of max. 9 % in accordance with paragraph 10 (1).■ Standard seasonal efficiency [to DIN] of at least 94 % in accordance with

paragraph 6 (2).

Allendorf, 22 February 2013 Viessmann Werke GmbH&Co KG

Authorised signatory Manfred Sommer

Certificates

Manufacturer's certificate according to the 1st BImSchV [Germany]

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AAdjusting the burner...........................18

BBoiler door■ Opening..........................................10■ Securing.........................................14Boiler water total hardness................17

CChecking the diaphragm expansion ves-sel......................................................15Checking the function of the safetyequipment..........................................15Checking the mixer for ease of operationand tightness......................................18Checking the system pressure...........15Checking the water quality.................16Cleaning cover■ Opening..........................................10■ Securing.........................................14Cleaning the sight glass in the boilerdoor....................................................18

DDraught stabiliser Vitoair■ Checking.........................................18■ Closing............................................10

FFill and top-up water..........................17Flue outlet cleaning............................12Flue pipe cleaning..............................12

HHeating surface cleaning...................12

IInstructing the system user................20

OOperating and service documents.....20

PParts list.............................................21

SSystem■ Commissioning.................................9■ Filling with water...............................9■ Venting.............................................9

TTurbulators■ Cleaning.........................................12■ Inserting..........................................13

WWater quality requirements................24

Keyword index

Keyword index56

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34

5692

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35

5692

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36

Applicability

Serial No.:7452973 7452974 7452975 74529767452977 7452978 7452979 7452980

Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: [email protected]

Viessmann Werke GmbH&Co KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com

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Documents

for contractors Service instructions Type SX2A , 90 to 560 ... · Service instructions for contractors Vitoplex 200 VIESMANN Type SX2A, 90 to 560 kW Oil/gas boiler For applicability,