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Viessmann Vitoplex 200 SX2A Service Instructions For Contractors

90 to 560 kw oil/gas boiler
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VIESMANN
Service instructions
for contractors
Vitoplex 200
Type SX2A, 90 to 560 kW
Oil/gas boiler
VITOPLEX 200
Please keep safe.
5692848 GB
9/2018

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Summary of Contents for Viessmann Vitoplex 200 SX2A

  • Page 1 VIESMANN Service instructions for contractors Vitoplex 200 Type SX2A, 90 to 560 kW Oil/gas boiler VITOPLEX 200 Please keep safe. 5692848 GB 9/2018...
  • Page 2 Danger system. Hot surfaces and fluids can lead to burns or Replace faulty components only with genuine scalding. Viessmann spare parts. Before maintenance and service work, switch ■ OFF the appliance and let it cool down. ■ Never touch hot surfaces on the boiler, burner,...
  • Page 3 For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...

  • Page 4: Table Of Contents

    Index Index Information Symbols ....................Intended use ..................Product information ................Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance Parts lists Ordering parts ..................17 Parts list ....................18 Parts list ....................20 Water quality Water quality requirements ..............22 Prevention of damage due to scaling ..........

  • Page 5: Symbols

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 6: Product Information

    Information Product information Vitoplex 200, type SX2A ■ Fuels: Fuel oil and natural gas Permissible operating pressure: Up to 560 kW 4 bar ■ (0.4 MPa); from 700 kW 6 bar (0.6 MPa) ■ Rated heating output 90 to 560 kW...
  • Page 7 Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • • 1. Commissioning the system....................• • • 2. Shutting down the system....................• • 3. Closing the Vitoair draught stabiliser (if installed)............•...

  • Page 8: Commissioning The System

    Commissioning, inspection, maintenance Commissioning the system Operating and service instructions for the control 10. Switch ON the mains isolator, the switch for the unit and the burner heating circuit pump and the burner ON/OFF switch, in that order. Observe the burner manufac- 01.

  • Page 9: Cleaning The Turbulators, Heating Surface, Flue Outlet And Flue Pipe

    Commissioning, inspection, maintenance Opening the boiler door and cleaning cover (cont.) Fig. 1 Cleaning the turbulators, heating surface, flue outlet and flue pipe 1. Remove turbulators without applying force. 2. Clean flues and combustion chamber with the brush. Remove combustion residues with a vacuum cleaner.

  • Page 10: Checking The Thermal Insulation Components On The Boiler Door

    Commissioning, inspection, maintenance Cleaning the turbulators, heating surface, flue… (cont.) 3. Use a vacuum cleaner to remove combustion resi- dues from the flue and the flue outlet through cleaning aperture in the flue outlet. Fig. 3 Checking all gaskets and packing cords on the flue gas side Checking the thermal insulation components on the boiler door Danger When working with high temperature insulation...

  • Page 11: Securing The Boiler Door And Cleaning Cover

    Commissioning, inspection, maintenance Inserting the turbulators (cont.) 1. Push turbulators approx. of their length into ¼ hot gas flues 2. Bend turbulators approx. 10 - 15°. 3. Push the turbulators into the hot gas flues as far as they will go. When doing this, check the pre-stress- ing.

  • Page 12: Checking The Function Of Safety Equipment

    Commissioning, inspection, maintenance Checking connections and sensor well on the heating water side for tight- ness Checking the function of safety equipment Check safety valves, water level and pressure limiter in accordance with manufacturer's instructions. Checking the function of the pressure switch Installation instructions, pressure switch set Checking the expansion vessel and system pressure Expansion vessel manufacturer's instructions...

  • Page 13: System Is Used (Dcc System)

    Commissioning, inspection, maintenance Checking the expansion vessel and system… (cont.) Observe the manufacturer's instructions. Limit pres- sure fluctuations to the lowest possible differential. Cyclical pressure fluctuations and more significant pressure differentials point towards a system fault. Immediately remedy such system faults, otherwise other heating system components may suffer damage.

  • Page 14: Cleaning The Sight Glass In The Boiler Door

    Commissioning, inspection, maintenance Cleaning the sight glass in the boiler door Sight glass with ventilation facility Fig. 6 Check the gaskets and hose connection for tightness. Checking the mixer for ease of operation and tightness 1. Remove the motorised lever from the mixer han- 3.
  • Page 15 Commissioning, inspection, maintenance Adjusting the burner (cont.) Rated heating Pressure drop on the hot gas Rated heating Pressure drop on the hot gas output side output side mbar mbar To protect the system against dew point corrosion, burner stage 2 (full heating output) must be set to the rated boiler heating output.

  • Page 16: Instructing The System User

    Commissioning, inspection, maintenance Adjusting the burner (cont.) Operation with burner load < 40 % The minimum system temperatures (flow/return) are 60/55 °C for oil operation and 70/65 °C for gas opera- tion. Instructing the system user The installer should instruct the user in the operation of the system.

  • Page 17: Ordering Parts

    Parts lists Ordering parts The following details are required when ordering parts: ■ Serial no. (see type plate ■ Position number of the part from this parts list Parts not shown Pos. Part Installation instructions Service instructions Thermal insulation, small parts Touch-up spray paint, Vitosilver Touch-up paint stick, Vitosilver Flame tube gasket...

  • Page 18: Parts List

    Parts lists Parts list Fig. 7 Boiler control unit, see service instructions for boiler control unit...
  • Page 19 Parts lists Parts list (cont.) Pos. Part Boiler door Studs Sight glass parts, comprising: pos. 004 to 007 Parts for sight glass frame Gasket Hose nozzle Plastic hose Hose pack Ø 18 mm Thermal insulation block Thermal insulation mat Packing GF 20 x 15 mm Cleaning brush (wearing part) Brush handle Extension piece...
  • Page 20 Parts lists Parts list Fig. 8 Type plate, on either the r.h. or l.h. side Burner cable, see service instructions for boiler control unit Therm-Control temperature sensor...
  • Page 21 Parts lists Parts list (cont.) Note on position 103 Rated heating output in kW Number Pos. Part Turbulator Gasket Cleaning cover Cleaning cover gasket Sensor well, boiler water temperature sensor Therm-Control sensor well Front panel, top Front panel, bottom Back panel, top Back panel, bottom Side panel, front right (with pos.

  • Page 22: Water Quality Requirements

    Water quality Water quality requirements Note Observation of the following requirements is a necessary condition for safeguarding your warranty rights. The warranty excludes damage due to water and scaling. Prevention of damage due to scaling Prevent excessive scale build-up (calcium carbonate) on the heating surfaces.

  • Page 23: Prevention Of Damage Due To Corrosion On The Water Side

    For pressure maintaining systems, see page 12. Using antifreeze in boilers Viessmann boilers are designed and built for water as ■ Antifreeze developed especially for heating systems a heat transfer medium. To protect boiler systems from...

  • Page 24: Water Quality

    Water quality Using antifreeze in boilers (cont.) If a boiler system is changed to operate without anti- To avoid the risk of corrosion, ensure that there is no ■ ■ freeze, flush the system in order to remove all traces difference in electrical potential between system of the antifreeze.

  • Page 25: Water Quality Table

    Commissioning/service reports Water quality table Meter reading Fill and top-up water Total water volume Total hardness pH value Date Feedwater Boiler water Maintenance/service report Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date:...
  • Page 26 Commissioning/service reports Maintenance/service report (cont.) Commissioning Maintenance/service Maintenance/service Date:...
  • Page 27 Specification Specification Rated heating output Rated heat input Permiss. flow temperature °C 110 (up to 120 °C on request) (= safety temperature) Permiss. operating temper- °C ature Permiss. operating pres- sure Pressure drop on the hot gas side mbar Boiler body dimensions Length excl.
  • Page 28 Specification Specification (cont.) Rated heating output Flue gas parameters Temperature (at 60 °C boiler water temperature) At rated heating output °C ■ At partial load °C ■ Temperature (at 80 °C boiler °C water temperature) Flue gas mass flow rate For natural gas kg/h 1.5225 x combustion output in kW...

  • Page 29: Final Decommissioning And Disposal

    Final decommissioning Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.

  • Page 30: Eu Declaration Of Conformity

    DIN V 4701-10 which is specified by the EnEV [Germany]. Manufacturer's certificate We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitoplex 200, type SX2A, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): limits according to paragraph 6 (1) ■...

  • Page 31: Keyword Index

    Keyword index Keyword index Boiler door Operating and service documents......16 – Opening..............8 – Securing..............11 Burner adjustment............14 Parts list..............17 Pressure maintaining systems........12 Pressure switch function, checking......12 Cleaning cover Product information............6 – Opening..............8 Pump controlled pressure maintaining systems..12 –...
  • Page 32 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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