Viessmann Vitoflex 300-RF Series Installation and user guide

Service and
Maintenance Instructions
for use by engineers and heating contractors
5603 880 - 03 12/2016
Read and save these instructions
for future reference.
Vitoflex 300-RF
Product may not be exactly as shown
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
Improper installation, adjustment and/or
operation could cause carbon monoxide
poisoning resulting in injury or loss of life.
This product must be installed and serviced
by a professional service technician who is
experienced and qualified in hot water boiler
installation and wood fuel combustion.
Do not store or use gasoline or other
flammable fluids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL FLUE GAS
Deactivate heating equipment
Open windows and doors.
Inform your heating contractor
Please file in Service Binder
WARNING
WARNING
IMPORTANT
H
Vitoflex 300-RF 150, 220, 300, 400 and 540
Wood-fired Boiler
Output range: RF 150 154 - 512 MBH (45- 150 kW)
RF 220 205 - 751 MBH (60- 220 kW)
RF 300 273 - 1024 MBH (80- 300 kW)
RF 400 341 - 1365 MBH (100- 400 kW)
RF 540 478 - 1843 MBH (140- 540W kW)

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Safety, Installation and Warranty Requirements
WARNING
Installers must follow local regulations with respect
to installation of carbon monoxide detectors. Follow
manufacturer’s maintenance schedule of the boiler
contained in the section “Cleaning and Maintenance”.
Please ensure that these instructions are read and understood before commencing service and/or maintenance. Failure
to comply with the instructions listed below and details printed in this manual can cause product/property damage,
severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed
information found in manual subsections).
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to Viessmann equipment.
For a listing of chemicals which
cannot be stored in or near the
boiler room, please see subsection
entitled “Mechanical Room”.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service.
Carbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.
For information pertaining to the proper
installation, adjustment, service and
maintenance of this equipment to avoid
formation of carbon monoxide, refer to
the installation and operating instructions.
Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Combustion Air Supply”.
Equipment venting
Never operate the boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
refer to the installation and operating
instructions. All products of
combustion must be safely vented
to the outdoors.
Introduction

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About these Instructions
Introduction
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.
CAUTION
Cautions draw your attention to the presence of potential
hazards or important product information.
WARNING

IMPORTANT
Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury
or substantial product/property damage.
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates to note additional information
This symbol indicates that other instructions must be
referenced.
Note: Viessmann Manufacturing Company Inc. reserves
the right to make product changes or updates
without notice and will not be held liable for
errors or omissions in the product literature.
Warnings draw your attention to the presence of potential
hazards or important product information.

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Table of Contents
Introduction
General Information
Safety
Maintenance
Troubleshooting
Safety, Installation and Warranty Requirements..............2
About these Instructions..............................................3
Product Information.....................................................5
Important Regulatory and Installation Requirements ........6
Safety Instructions......................................................8
Carbon Monoxide........................................................9
Extreme Weather Conditions......................................10
HazardousMaterial....................................................11
Mechanical Room.....................................................12
Combustion Air Supply..............................................13
Components of the Biomass Boiler..............................14
Cleaning..................................................................15
Boiler.................................................................15
Heat exchanger displacement rods........................16
Installing the displacement rods.............................16
Removing the displacement rods...........................16
Flue gas cyclone (optional)....................................17
Pneumatic cleaning system (optional)...................17
Feed systems...........................................................18
Shutdown...............................................................19
Boiler..................................................................19
Extraction and conveyance systems.......................19
Control system....................................................19
Replacing the buffer battery..................................19
Ash disposal........................................................19
Disposal of the boiler............................................19
Instructions regarding removal...............................19
Waste disposal....................................................19
Performance Problems...............................................20
Grate Drive Mechanics Jams.....................................21
Checking for increased Wear of Fireclay......................22
Checking the Inside of the Boiler Door.........................23
Checking the Oxygen Control System.........................24
Balancing the Oxygen Sensor.....................................25
Heating System Faults..............................................26
Loader System Faults................................................27
Page

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Maximum allowable working pressure (water)…30 or 60 psi
Maximum water temperature…250°F (120°C) (closed loop)
Maximum boiler temperature……210°F (99°C) (open loop)
This boiler does not require a flow switch.
Viessmann solid-fuel boiler can only be installed and
serviced by qualified trained personnel.
Steel wood-fired hot water heating boiler.
For operation primarily with modulating boiler water
temperatures in closed loop forced circulation hot water
heating systems. Under certain conditions, open loop
systems may also be considered. Contact Viessmann
for details.
WARNING
Exposing the boiler to pressures and temperatures in
excess of those listed will result in damages and will
render the warranty null and void.
Product Information
General Information
Codes and standards
CSA B366.1-M91
Solid Fuel Fired Central Heating Appliances
CSA C.22.2#3-M88 (R2004)
Electrical Features of Fuel Burning Equipment
UL2523
Solid Fuel-Fired Hydronic Heating Appliances, Water Heat-
ers and Boilers
CSA B365-10
Installation Code for Solid Fuel Burning Appliances
and Equipment
ASME section IV boilers and pressure vessels

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Vitoflex 300-RF Service & Maintenance
Important Regulatory and Installation Requirements
Working on the equipment
The installation, adjustment, service, and maintenance
of this boiler must be done by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water boilers.
Ensure main power supply to equipment, the heating
system, and all external controls have been deactivated.
Take precautions to avoid accidental activation of power
during service work.
The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. These include low-water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies.
This product comes with several safety instruction
labels attached.
Do not remove!
Contact Viessmann immediately if replacement labels
are required.
Please carefully read this manual prior to attempting
service and maintenance. Any warranty is null and void
if these instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference documentation
of the respective product.
We offer frequent installation and service seminars to
familiarize our partners with our products. Please inquire.
RISK OF INJURY: Shut the system off before starting
any cleaning. Be absolutely sure to wear protective
gloves, protective eyewear if required and use the
cleaning tools that come with the system (danger of
blow-ups, burns and getting crushed)!
CAUTION
Technical literature
Literature applicable to all aspects of the Vitoflex 300-RF
wood-fired boiler:
- Installation and Operating Instructions
- Service and Maintenance Instructions
- Field Wiring Diagram
General Information

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Vitoflex 300-RF Service & Maintenance General Information
WARNING
The boiler must not be located in areas or rooms where
chemicals are stored or aggressive vapors from (i.e.
bleach, hair spray, methyl chloride, carbon tetrachloride
or perchloroethylene) or high dust levels or humidity
levels are present. Heat exchanger corrosion might
occur and reduce the lifetime of the boiler significantly.
If above criteria are not properly observed and boiler
damage results, any warranty on the complete boiler
and related components will be null and void.
Important Regulatory and Installation Requirements (continued)
Regular maintenance and service
The entire heating system must be cleaned and serviced
on a regular basis by a qualified contractor or service
agency to ensure reliable, energy-efficient, and
environmentally friendly operation.
The build-up of soot on the heat exchanger raises the
flue gas temperature and reduces efficiency.
IMPORTANT
Keep boiler and boiler room clear and free of combustible
materials, gasoline and other flammable vapors and
liquids. Do not obstruct the flow of combustion and
ventilation air. All inspection, maintenance and service
must be performed by a qualified heating contractor.
WARNING
Improper installation, adjustment, service or maintenance
can cause flue products to flow into living space. Flue
products contain poisonous carbon monoxide gas, which
can cause nausea or asphyxiation resulting in severe
personal injury or loss of life.
WARNING
Service and maintenance can only be performed by a
qualified heating contractor.
Important to know
Do not use this boiler if any part has been under, or
exposed to, water. Immediately call a qualified heating
contractor to inspect the boiler and to replace any
part of the control system, which has been under or
exposed to water.

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If you notice fire coming from the appliance, call the fire
department immediately!
DO NOT attempt to extinguish the fire unless qualified to
do so.
WARNING
Fire causes a risk of burns and explosion!
Shut down the boiler
Close fuel shut-off valves
Use a tested fire extinguisher, class ABC.
Safety Instructions
IMPORTANT
The local building codes and regulations must be followed
by the heating contractor.
IMPORTANT
Please refer to the Installation and Operating
Instructions for installation, commissioning
and technical specification information. The
“Installation and Operating Instructions” contain
the necessary safety and national/local code
requirements which, if not followed exactly,
may lead to property damage, personal injuries
and/or death.
Important Information
Safety instructions
When carrying out work on the heating system, such as
cleaning and maintenance, wear appropriate protective
equipment when required.
There is a danger of getting injured through: burning,
knocking against corners and edges, crushing in moving
parts and noise.
Power supply: 120V or 240V/1/ and 208V/3/ 60Hz
In case of an emergency, the Vitoflex 300-RF can be
disconnected from the electrical power supply at all the
leads by the main switch on the control cabinet.
CAUTION
FIRE HAZARD:
The boiler must NEVER be operated with the doors open!
Any burning bits that escape could start a fire.
RISK OF INJURY:
If the doors are open during operation, sparks or flames
could leap out.
Equipment for dissipating excess heat: a competent
specialist should examine the operational reliability of
the thermal safety flush valve annually. The safety
heat exchanger must not by any means be used as an
operational heat exchanger.
Seals: for the functioning and controllability of the boiler,
it is important that no unwanted air can enter unchecked
through leaks.
The doors and lids have to shut tight - any damaged
seals must be replaced immediately. Tighten the retaining
screws and handles well.
Operation, cleaning and maintenance: bear in mind that
even the best product can only fulfill its functions well,
doing so for a long time and free of malfunctions, if
operated and maintained properly.
Compliance with the “Cleaning” section is mandatory!
IMPORTANT
Doors: for safety keep firing and ash pit doors tightly closed
Safety

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Carbon Monoxide
Carbon monoxide
The U.S. Consumer Product Safety Commission strongly
recommends the installation of carbon monoxide detectors
in buildings in which wood-burning equipment is installed.
Carbon monoxide (CO) is a colorless, odorless gas, which
may be produced during incomplete combustion of fuel
and/or when the flame does not receive an adequate
supply of combustion air. Carbon monoxide can cause
severe personal injury or loss of life.
Therefore, carbon monoxide detectors that are in
compliance with a nationally recognized standard
(e.g. ANSI/UL 2034-2002, CSA 6.19-01) should be
installed and maintained in buildings that contain
wood-burning equipment.
Note: Viessmann does not test any detectors and makes
no representation regarding any brand or type of
detector.
For safe operation
We recommend that you frequently:
- Check for debris which could obstruct the flow of
flue gases. The vent or chimney must not be blocked.
A blocked or partially blocked vent or
chimney can cause flue gases to leak into the
structure. Flue gases leaking into the house can
cause injury or death. Blocked or partially blocked
chimneys must have the blockage removed by a
qualified heating contractor.
- Check pressure gage for correct system (water)
pressure. Check for water on the floor from the
discharge pipe of the pressure relief valve or any
other pipe, pipe joint, valve or air vent.
- Check for moisture, water, or appearance of rust
on the flue gas pipes, their joints as well as vent
dampers, or side wall vent terminals (if so equipped).
- Ensure that nothing is obstructing the flow of
combustion and ventilation air and no chemicals,
garbage, gasoline, combustible materials, flammable
vapors and liquids are stored (not even temporarily)
in the vicinity of the boiler.
- DO NOT allow unsupervised children near the boiler.
Service/inspection of the boiler and the system must be
performed on a regular basis. Maintenance, service and
cleaning are specified in the section “Maintenance”.
Before the heating season begins, it is recommended that
the boiler be serviced by a qualified heating contractor.
WARNING
Improper installation, adjustment, service or maintenance
can cause flue products to flow into living space. Flue
products contain poisonous carbon monoxide gas, which
can cause nausea or asphyxiation resulting in severe
personal injury or loss of life.
WARNING
The operator/ultimate owner is required to have the heating
boiler and controls checked, as a minimum once per year,
by the original installer or by a competent heating
contractor familiar with the equipment. Defects must
be corrected immediately.
Safety

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Safety
Extreme Weather Conditions
WARNING
As there are no user-serviceable parts on the boiler,
or control, the end-user must not perform service
activities of any kind on system components. Failure
to heed this warning can cause property damage,
severe personal injury or loss of life.
Frozen water pipe hazard
Your heating boiler is designed to provide a warm and
comfortable living environment. It is NOT designed to
ensure against freezing of water pipes. The boiler is
equipped with several safety devices that are designed
to shut down the boiler and to prevent it from
restarting in the event of various unsafe conditions.
If your boiler remains off for an extended period of time
during cold weather, water pipes may freeze and burst,
resulting in extensive water damage and conditions in
which mold could grow. Certain molds are known to
cause respiratory problems, as well as to pose other
serious health risks. In case of water damage, immediate
measures should be taken to dry out affected areas as
quickly as possible to prevent mold from developing.
If the building will be unattended for an extended period
of time during cold weather, you should...
Shut off the water supply to the building, drain the water
pipes and add antifreeze for potable water to drain traps
and toilet tanks. Open faucets where appropriate.
or…
Have someone check the building frequently during cold
weather and call a qualified service agency if required.
or...
Install a reliable remote temperature sensor that will notify
somebody of freezing conditions within the building.