Viessmann VITOLADENS 300-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitoladens 300-T
Type VW3B, 33 to 50 kW
Oil Unit condensing boiler
For applicability, see the last page
VITOLADENS 300-T
5692 906 GB 7/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified contractors.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ Isolate the system from the power sup-
ply (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 unau-
thorised reconnection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
Before beginning work, earthed
objects, such as heating or water
pipes, must be touched to dissi-
pate any static charge.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
5692 906 GB

3
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 906 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Parts lists............................................................................................................ 15
Commissioning/service reports........................................................................ 20
Specification....................................................................................................... 21
Certificates
Declaration of conformity...................................................................................... 22
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 23
Index
Index
5692 906 GB

5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system on the heating water side. 6
• • 2. Shutting down the system
• • 3. Opening the boiler door................................................. 7
• • 4. Cleaning the heating surfaces....................................... 8
• • 5. Checking gaskets and thermal insulation
components.................................................................... 9
• • 6. Closing the boiler door.................................................. 10
• • 7. Separating the neutralising system or active charcoal
filter (if installed) from the boiler and connecting the
drain hose........................................................................ 11
• • 8. Checking the neutralising system (if installed)........... 11
• • 9. Checking the active charcoal filter (if installed).......... 12
• • 10. Checking the connections on the flue gas side for
tightness.......................................................................... 12
• • 11. Cleaning the condensate drain pipe and siphon and
reconnecting to the drainage system........................... 12
••• 12. Checking the connections on the heating water and
DHW sides for leaks
••• 13. Checking the function of safety valves
• • 14. Checking the diaphragm expansion vessel and
system pressure............................................................. 13
••• 15. Checking the thermal insulation for firm seating
• • 16. Checking the mixer for ease of operation and leaks... 13
••• 17. Checking the ventilation air connection to the burner
(if installed)...................................................................... 13
••• 18. Adjusting the burner...................................................... 13
•19. Instructing the system user........................................... 13
•20. Operating and service instructions.............................. 14
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 906 GB

6
Filling the heating system on the heating water side
A
B
1. Close shut-off valve B in the return
line.
2. If using a top-mounted Divicon
(accessory):
Set the mixer lever to "OPEN" (red).
3. Fill the system via fill valve A on the
heating water return, until it is fully
vented.
4. Open shut-off valve B again.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 906 GB

7
Opening the boiler door
40/50 kW
41
Balanced flue operation: Remove venti-
lation air pipe before opening the door.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

8
Cleaning the heating surfaces
A
ACleaning brush
Note
Carry out standard cleaning from the
front of the boiler (through the combus-
tion chamber).
In the case of severe contamination (e.g.
through incorrect burner adjustment),
remove the heat exchanger to clean the
boiler.
1. Remove contamination from the con-
nector using a vacuum cleaner.
2. Thoroughly flush the heating surfa-
ces with water.
!Please note
Prevent components that come
into contact with flue gas from
being scratched or otherwise
damaged. Prevent components
that come into contact with flue
gas from contact with pure iron,
as corrosion damage can result.
Never use a wire brush or sharp
objects. Use plastic brushes if
required.
For conventional cleaning, thoroughly
flush the heating surfaces with water.
You may use cleaning agents if you
notice stubborn residues, surface disco-
louration or soot deposits.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

9
For this, observe the following:
■ Only use solvent-free cleaning agents.
Ensure that no cleaning agent gets
between the boiler body and the ther-
mal insulation
■ Remove soot deposits with alkaline
agents containing surfactant additives
(e.g. Fauch 600*1)
■ Combustion residues may create thin,
yellow-brown surface discolouration
as well as hard deposits that may only
become visible after removing the soot
deposits. Use slightly acidic, chloride-
free cleaning agents based on phos-
phoric acid to remove surface disco-
louration and hard deposits (e.g. Antox
75 E*1)
■ Remove loose deposits from the heat
exchanger; thoroughly flush the heat-
ing surfaces with water
Cleaning agent manufacturer's
details
Checking gaskets and thermal insulation components
1. Check gaskets and packing cords in
the boiler door for damage.
2. Check the thermal insulation compo-
nents in the combustion chamber and
the boiler door for damage.
3. Replace any damaged parts.
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchen-
gladbach.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

10
Closing the boiler door
40/50 kW
Note
Tighten the screws diagonally.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

11
Separating the neutralising system or active charcoal filter (if
installed) from the boiler and connecting the drain hose
B C A
1. Separate hose A to the neutralising
system from siphon B.
2. Connect drain hose C to the con-
densate drain of the siphon and run
to a drainage system.
Checking the neutralising system (if installed)
1. Check the pH value of the conden-
sate downstream of the neutralising
system with a pH test strip. Replace
the granulate if the pH value is
< 6.5.
Note
Part no. for pH test strips: 9517 678.
Observe the neutralising system
manufacturer's instructions.
2. Refit neutralising system in reverse
order.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

12
Checking the active charcoal filter (if installed)
Observe the active charcoal filter manu-
facturer's instructions.
Checking the connections on the flue gas side for tightness
A
B
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation strip A
and pull thermal insulation mat B
out a little.
2. Check the heat exchanger fixings for
firm seating.
3. Check the connector on the heat
exchanger for leaks.
Cleaning the condensate drain pipe and siphon and reconnect-
ing to the drainage system
Check that the hoses are routed without
kinks and that the condensate can drain
freely.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

13
Checking the diaphragm expansion vessel and system pressure
Note
Observe the diaphragm expansion ves-
sel manufacturer's instructions.
Carry out this test on a cold system.
1. Drain the system until the pressure
gauge indicates "0" or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure in
this vessel.
2. If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static system pressure, top
up with nitrogen until the pre-charge
pressure is 0.1 to 0.2 bar higher.
3. Top up with water until the charge
pressure of the cooled system is 0.1
to 0.2 bar higher than the pre-charge
pressure of the diaphragm expansion
vessel.
Permiss. operating pressure: 3 bar.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the
mixer handle and check the mixer for
ease of operation.
2. Check the mixer for leaks. Replace
the O-rings if the mixer is leaking.
Checking the ventilation air connection to the burner (if installed)
For balanced flue operation, check the
ventilation air connection for damage.
Adjusting the burner
Burner service instructions
Instructing the system user
The installer must instruct the user in the
operation of the system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

14
Operating and service instructions
1. Complete and detach the customer
registration 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 hand
this over to the system user.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 906 GB

15
When ordering spare parts:
Quote the part no. and serial no. (see
type plate) and the position number of
the required part (as per this parts list).
Obtain standard parts from your local
supplier.
001 Boiler door (with pos. 002 and 003)
002 Gasket 16 x 12 mm
003 Thermal insulation block for the
boiler door
006 Hinge pin
008 Combustion chamber VHG
009 Gaskets (3 pce)
010 Sealing washer 45 x 3 mm
011 Cap G 1½
012 Brush handle
025 Ventilation air hose
028 Ventilation air hose adaptor
030 Silencer
031 Flue gas connection
032 Heat exchanger with gaskets pos.
036 and 041
033 Connection pipe
034 Seal ring
035 Boiler flue connection
036 Gaskets
038 Connection line
039 Siphon, complete
040 Boiler flue connection with spacer
ring
041 Gasket
042 Flue gas gasket
044 Spring hooks
045 Ventilation air hose
046 Hose clip
047 Air inlet
048 Bypass valve
049 Siphon
050 Corrugated hose
051 Gasket
052 Siphon mounting plate
200 Front panel (with pos. 214 and 303)
201 Back panel (with pos. 212)
203 Top panel
205 Side panel
206 Thermal insulation mat, back panel
207 Thermal insulation mat, front panel
208 Thermal insulation jacket
212 Edge protector
213 Logo
214 Cap
215 Retaining bracket, front
216 Retaining bracket, back
217 2–fold strain relief
218 Thermal insulation, connection line
219 Thermal insulation, heat exchanger
220 Thermal insulation mat, heat
exchanger, back
221 Thermal insulation mat, flue pipe
222 Thermal insulation mat, heat
exchanger
310 Plug M 14 with O-ring (only for
33/35.4 kW)
311 Plug M 14 with sealing sleeve (only
for 33/35.4 kW)
312 Plug (only for 33/35.4 kW)
313 Sealing set, test port, 2 pce (only for
40/42.8 and 50/53.7 kW)
Wearing part
013 Cleaning brush
Parts not shown
300 Spray paint, Vitosilver
301 Touch-up paint stick, Vitosilver
302 Fitting elements, thermal insulation
303 Decorative adhesive tape
305 Installation instructions
306 Service instructions
309 Connecting elements
Parts lists
Parts lists
5692 906 GB

16
ABoiler control unit (see separate
parts list)
BBoiler type plate, either on the l.h. or
r.h. side
CHeat exchanger type plate, either on
the l.h. or r.h. side
Parts lists
Parts lists (cont.)
5692 906 GB

17
A
201 212 206
200
208
203205
205
207214
215
216
216
215
213
217 B C
Parts lists
Parts lists (cont.)
5692 906 GB

18
011
010
009
008
013
012
028
046
047
025
046
006
030
309
309
002 003
001
Parts lists
Parts lists (cont.)
5692 906 GB

19
049
219
036
047
046
222
045
046
035
220
041
031
309
038
036
033
038
036
218
033
036
044 221 036
036
034
042
042
040
032
036
048
050
051
051
042
049
050
051
039
310
313
312
311
311
312
313
052
313
310
047
313
Parts lists
Parts lists (cont.)
5692 906 GB

20
Commissioning Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
Commissioning/service reports
5692 906 GB