Viessmann VITOPLEX 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 300
Type TX3A, 620 to 2000 kW
Oil/gas boiler
VITOPLEX 300
5692798 GB 9/2020 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material losses.
Safety instructions explained
Danger
This symbol warns against the risk
of injury.
!Please note
This symbol warns against the risk
of material losses and environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on gas installations may only be
carried out by a registered gas fitter.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
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 safe-
guard it against unintentional reopen-
ing.
■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 recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
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Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not smoke. Prevent naked
flames and sparks. Never switch
lights or electrical appliances 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 sup-
ply utility from outside the building.
■Have the power supply to the
building shut off from a safe place
(outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic 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 condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
5692798

5
Danger
The simultaneous operation of the
boiler and appliances that exhausts
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692798

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1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
System examples .................................................................................. 8
Spare parts lists ..................................................................................... 8
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
3. Water quality Water quality requirements .................................................................... 18
■Heating systems with rated operating temperatures up to 100 °C
(VDI 2035) .......................................................................................... 18
■Prevention of damage through corrosion on the water side ............... 19
Using antifreeze in boilers ..................................................................... 19
4. Commissioning/service
reports
Water quality .......................................................................................... 21
Maintenance/service .............................................................................. 21
5. Specification ................................................................................................................ 23
6. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 24
7. Certificates EU Declaration of Conformity ................................................................ 25
Manufacturer's certificate according to BImSchV .................................. 25
8. Keyword index ................................................................................................................ 26
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
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 up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Symbols
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Vitoplex 300, type TX3A
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 6 bar (0.6 MPa)
■Rated heating output 620 to 2000 kW
System examples
Available system examples: See
www.viessmann-schemes.com.
Spare parts lists
Information about spare parts can be found at
www.viessmann.com/etapp or in the Viessmann
spare part app.
Information
Product information
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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 10
• • 2. Shutting down the system................................................................................................. 10
• • 3. Opening the boiler door and cleaning cover................................................................... 11
•4. Cleaning the internal pipes, heating surface, flue outlet and flue pipe........................ 11
• • 5. Checking all gaskets and packing cords on the flue gas side
• • 6. Checking the thermal insulation components on the boiler door................................. 12
•7. Inserting internal pipes; securing the boiler door and cleaning cover......................... 13
• • 8. Checking connections and sensor well on the heating water side for tightness
• • 9. Checking the function of safety equipment..................................................................... 13
••• 10. Checking the function of the pressure switch................................................................ 14
• • 11. Checking the expansion vessel and system pressure................................................... 14
•12. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 15
• • 13. Checking the firm seating of electrical plug-in connections and cable grommets
• • 14. Checking the thermal insulation
• • 15. Checking the water quality................................................................................................ 15
• • 16. Cleaning the sight glass in the boiler door...................................................................... 15
•17. Checking the mixer for ease of operation and tightness............................................... 15
•18. Checking the function of the return temperature raising facility (if installed)
• • 19. Checking the installation room ventilation
• • 20. Checking the flue pipe for tightness
•21. Adjusting the burner.......................................................................................................... 16
•22. Instructing the system user.............................................................................................. 17
•23. Operating and service documents................................................................................... 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating and service instructions for the control
unit and the burner
01. Close the gas shut-off valve and open the boiler
door.
02. Check internal pipes C are correctly inserted into
hot gas flues B. Spring clip D of the internal
pipes must lock into place behind first constriction
E.
Fig. 1
AInternal pipe extractor
03. Check that the ventilation air aperture in the instal-
lation room is open.
04. Fill the heating system with water and vent the
system.
Permissible operating pressure: 6 bar (0.6 MPa)
05. Record the amount of fill water and its hardness in
chapter "Checking the water quality".
!Please note
Unsuitable water quality can damage the
boiler body.
Operate boilers only with softened water.
Observe the instructions in chapter "Water
quality requirements" on page 18.
06. Check the system pressure.
07. Check the oil level or the gas supply pressure.
08. Open the flue gas damper (if installed).
09. Check that the cleaning aperture on the flue outlet
is closed.
10. Open the shut-off valves in the oil or gas line.
11. Switch ON the mains isolator, the switch for the
heating circuit pump and the burner ON/OFF
switch, in that order. Observe the burner manufac-
turer’s operating instructions.
12. The dew point range must be cleared as quickly
as possible. For this reason prevent all heat sup-
ply to consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
!Please note
During boiler heat-up, unpleasant fumes
and odours can result from outgassing from
the thermal insulation, the thermal block
and the paint.
Ventilate the room during commissioning.
13. Once the flow temperature has been reached,
successively switch on the heat consumers.
Switch the burner over to automatic mode.
!Please note
Internal gas emissions from the thermal
block can lead to increased CO values in
the flue gas.
Continue to operate the boiler until a decline
can be clearly recognised.
14. Check all gaskets and plugs, and retighten if nec-
essary.
15. Check the boiler door and cleaning cover after
approx. 50 hours run and retighten all screws.
Shutting down the system
1. Switch OFF the mains isolator or the power supply,
and safeguard against unauthorised reconnection.
2. Interrupt the burner power supply. If installed, pull
plug-in connectors fA and lÖ from the burner.
3. Close the gas shut-off valve.
Danger
Heating water escaping under pressure will
injure bystanders.
Only open the connections on the heating water
side after the boiler has been depressurised.
Commissioning, inspection, maintenance
Commissioning the system
5692798