Viessmann PV1B, Service Instructions Manual

Page 1: ...Service instructions for contractors VIESMANN Vitoplex 100 Type PV1B 780 to 2000 kW 08 to 13 Oil gas boiler VITOPLEX 100 5461424 GB 9 2018 Please keep safe ...

Page 2: ...cable standards a ÖNORM EN ÖVGW G K directives ÖVGW TRF and ÖVE c SEV 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 ...

Page 3: ...c 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...

Page 4: ...uality requirements 22 Heating systems with rated operating temperatures up to 100 C VDI 2035 22 Prevention of damage through corrosion on the water side 22 Using antifreeze in boilers 23 5 Commissioning service reports Water quality 24 Maintenance service 24 6 Specification 26 7 Decommissioning and dis posal Final decommissioning and disposal 27 8 Certificates EU Declaration of Conformity 28 Manu...

Page 5: ...on 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...

Page 6: ...6 Vitoplex 100 type PV1B Fuels Fuel oil and natural gas Permissible operating pressure 6 bar 0 6 MPa Rated heating output 780 to 2000 kW Information Product information 5461424 Information ...

Page 7: ...ter side and the sensor well for leaks 11 Checking the function of safety equipment 12 12 Checking the function of the pressure switch 12 13 Checking the expansion vessel and system pressure 12 14 Checking electrical plug in connections and cable grommets for firm seating 15 Checking the thermal insulation for firm seating 16 Checking the water quality 13 17 Cleaning the sight glass in the boiler ...

Page 8: ...also applies when restarting after main tenance and cleaning work Please note During the initial boiler heat up unpleasant fumes and odours can result from outgas sing from the thermal insulation the thermal insulation block and the paint Ventilate the room during commissioning 12 After the flow temperature has been reached switch ON the heat consumers in sequence and change the burner over to aut...

Page 9: ... dust may develop This fibre dust can be harmful to health Only trained personnel may adjust or replace the insulation Wear suitable protective clothing especially breathing equipment and safety gog gles Cleaning cover The version of cleaning cover on the flue gas collector depends on the output rating Commissioning inspection maintenance Opening the boiler door and cleaning cover 5461424 ...

Page 10: ... cleaning cover on the flue gas col lector depends on the output rating Checking all gaskets and packing cords on the flue gas side Checking the thermal insulation components on the boiler door Inserting the turbulators Please note Some burner settings and specific system condi tions can cause the turbulators to move forward and be burnt as a consequence This can also lead to damage to the thermal...

Page 11: ...ot easily be pulled out of the hot gas flues Securing the boiler door and cleaning cover Note On gas burners disconnect the gas supply pipe Danger Escaping gas leads to a risk of explosion Check all gas connections for tightness 4x A Fig 5 Torque Screws A boiler door 25 Nm Screws cleaning cover 7 Nm Danger Leaks can result in a risk of poisoning through escaping gas Check gaskets carefully Commiss...

Page 12: ... 1 Drain the system until the pressure gauge shows 0 Alternatively close the cap valve on the expansion vessel and reduce the pressure in the expansion vessel Note The pre charge pressure of the expansion vessel p0 is made up of the static system pressure pSt static head and a supplement p0 pSt sup plement The supplement depends on the high limit safety cut out setting The following applies 100 C ...

Page 13: ...s with atmospheric deaeration through cyclical pressure release effect a central post ventilation of the heating system They do not provide oxygen removal in the sense of corrosion protection as described in VDI 2035 Part 2 Note Check the pressure maintaining system in line with the manufacturer s instructions Please note Cyclical pressure fluctuations and more signifi cant pressure differentials ...

Page 14: ...cking the installation room ventilation Checking the flue pipe for tightness Adjusting the burner For burner adjustment see separate burner documentation Adjust the maximum oil or gas throughput of the burner to the rated boiler heating output Rated heating output Pressure drop on the hot gas side fuel oil 2 kW Pa mbar 780 350 3 5 950 450 4 5 Rated heating output Pressure drop on the hot gas side ...

Page 15: ...llector Install a motorised flue gas damper Set the minimum runtime of the boiler to 10 min This extends the service life and reduces running costs Operating and service documents 1 Complete and detach the customer registration card Hand the system user their section for safekeep ing Retain the heating contractor s section 2 File all parts lists operating and service instruc tions in the folder an...

Page 16: ...16 Commissioning inspection maintenance Operating and service documents cont 5461424 ...

Page 17: ...arts Serial no see type plate Position number of the part from this parts list Parts not shown Pos Part 0001 Touch up spray paint Vitosilver 0002 Touch up paint stick Vitosilver 0003 Installation instructions Parts lists Ordering parts 5461424 Components ...

Page 18: ...18 0013 0010 0015 0011 0001 0012 0008 0009 0007 0006 0005 0015 0016 0004 0002 0014 0004 0003 Fig 7 Parts lists Boiler body assembly 5461424 Components ...

Page 19: ...011 Turbulator extractor 0012 Gasket DN 100 125 150 0013 Gasket DN 50 65 0014 Sensor well 0015 Glass fibre reinforced fabric tape 0016 Cleaning cover 3 0017 Cleaning brush wearing part Information on pos 0010 Rated heating output kW 780 950 1120 1350 1700 2000 Number of turbulators 48 56 66 68 76 70 3 Version depends on output rating For 1700 2000 kW 2 round cleaning covers Parts lists Boiler body...

Page 20: ...0024 0022 0023 0003 0003 0004 0009 0003 0003 0005 0008 0006 0010 0007 0004 0003 0003 0009 0003 0003 0004 0012 0013 0025 0006 0008 0015 0014 0016 0007 0006 0011 0019 0019 0017 Fig 8 Parts lists Thermal insulation assembly 5461424 Components ...

Page 21: ...11 Vitoplex 100 logo 0012 Thermal insulation jacket 0013 Thermal insulation jacket centre 0014 Thermal insulation mat top back 0015 Thermal insulation mat lower back 0016 Back panel top 0017 Back panel bottom 0018 Mounting bracket rear panel 0019 Edge protector 0020 Mounting bracket 0021 Mounting bracket fascia 0022 Cable trunking lower section 0023 Trunking retainer 0024 Cable trunking upper sect...

Page 22: ...orrosion on the water side The corrosion resistance of ferrous materials on the heating water side of heating systems and heat gener ators depends on the absence of oxygen in the heating water The oxygen introduced into the heating system with the first fill and subsequent top ups reacts with the sys tem materials without causing damage The characteristic blackening of the water after a cer tain t...

Page 23: ... valves other types of valves gaskets etc If the system is filled with antifreeze it must be marked accordingly If a boiler system is changed to operate without anti freeze flush the system in order to remove all traces of the antifreeze The quality of the boiler water and feedwater must meet the requirements of Directive VDI 2035 The systems must be designed as sealed unvented systems as the anti...

Page 24: ...r Boiler wa ter Medium Dosing volume m3 m3 m3 Maintenance service Commissioning Maintenance service Maintenance service Date By Commissioning Maintenance service Maintenance service Date By Commissioning Maintenance service Maintenance service Date By Commissioning service reports Water quality 5461424 Appendix ...

Page 25: ...25 Commissioning Maintenance service Maintenance service Date By Commissioning Maintenance service Maintenance service Date By Commissioning service reports Maintenance service cont 5461424 Appendix ...

Page 26: ... a boiler water tempera ture of 80 C At rated heating output C 215 At partial load 60 C 155 Product ID CE 0085BP0365 Standard seasonal efficiency to DIN for operation with fuel oil natural gas At heating system temperature 75 60 C 88 Hs gross cv Specification Specification 5461424 Appendix ...

Page 27: ...ot part of ordi nary household waste For decommissioning the system isolate the system from the power supply and allow components to cool down where appropriate All components must be disposed of correctly Decommissioning and disposal Final decommissioning and disposal 5461424 Appendix ...

Page 28: ...0 type PV1B as part of EC type testing can be used to assess the energy efficiency of heating and ventilation systems in buildings to DIN V 4701 10 as specified by the EnEV Germany see Specification table Manufacturer s certificate We Viessmann Werke GmbH Co KG D 35107 Allendorf confirm that the product Vitoplex 100 type PV1B complies with the following conditions stipulated by the 1st German Immi...

Page 29: ...nded use 5 M Maintenance service report 24 Manufacturer s certificate 28 Mixer check 14 O Operating and service documents 15 P Parts Boiler body 18 Ordering 17 Thermal insulation 20 Pressure switch function checking 12 Product information 6 Pump controlled pressure maintaining systems 13 S Safety equipment checking 12 Setting of temperature controller 12 Sight glass cleaning 14 Specification 26 Sy...

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Page 32: ... Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5461424 Subject to technical modifications ...