Viessmann VITOPLEX 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 300
Type TX3A, 90 to 500 kW
Oil/gas boiler
VITOPLEX 300
5692818 GB 9/2018 Please keep safe.

2
Please follow these safety instructions 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied 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 person 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
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, 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 a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
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 pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5692818

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances 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 supply 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 spreading.
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 conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion 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-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
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 suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692818

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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Parts list Ordering parts ........................................................................................ 17
■Parts not shown .................................................................................. 17
Parts list ................................................................................................. 18
Parts list ................................................................................................. 20
4. Water quality Water quality requirements .................................................................... 22
■Prevention of damage due to scaling ................................................. 22
■Prevention of damage due to corrosion on the water side ................. 23
Using antifreeze in boilers ..................................................................... 23
5. Commissioning/service
reports
Water quality .......................................................................................... 25
Maintenance/service .............................................................................. 25
6. Specification ................................................................................................................ 27
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 29
8. Certificates EU Declaration of Conformity ................................................................ 30
Manufacturer's certificate according to the 1st BImSchV ...................... 30
9. Keyword index ................................................................................................................ 31
Index
Index
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5
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
5692818
Information

6
Vitoplex 300, type TX3A
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 4 bar (0.4 MPa)
■Rated heating output 90 to 500 kW
Information
Product information
5692818
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Commissioning the system............................................................................................... 8
• • 2. Shutting down the system................................................................................................. 8
• • 3. Closing the Vitoair draught stabiliser (if installed)......................................................... 8
• • 4. Opening the boiler door and cleaning cover................................................................... 8
•5. Cleaning the internal pipes, heating surface, flue outlet and flue pipe........................ 9
••• 6. Checking all gaskets and packing cords on the flue gas side...................................... 10
• • 7. Checking the thermal insulation components on the boiler door................................. 10
•8. Inserting the internal pipes............................................................................................... 11
• • 9. Securing the boiler door and cleaning cover.................................................................. 11
••• 10. Checking connections and sensor well on the heating water side for tightness
••• 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 the setting of the temperature controller if a building management
system is used (DCC system)........................................................................................... 13
••• 15. Checking electrical plug-in connections and cable grommets for firm seating
••• 16. Checking the thermal insulation
• • 17. Checking the water quality................................................................................................ 14
• • 18. Cleaning the sight glass in the boiler door...................................................................... 14
••• 19. Checking the mixer for ease of operation and tightness............................................... 14
••• 20. Checking the function of the return temperature raising facility (if installed)
••• 21. Checking the installation room ventilation
••• 22. Checking the flue pipe for leaks
• • 23. Checking the Vitoair draught stabiliser (if installed)...................................................... 15
• • 24. Adjusting the burner.......................................................................................................... 15
•25. Instructing the system user.............................................................................................. 16
•26. Operating and service documents................................................................................... 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating and service instructions for the control
unit and the burner
01. Check that the internal pipes are fully inserted into
the hot gas flues; open the boiler door for this. See
chapter "Inserting the internal pipes", page 11.
02. Check that the ventilation air aperture in the instal-
lation room is open.
03. Fill the heating system with water and vent the
system.
Permissible operating pressure: 4 bar (0.4 MPa)
!Please note
Unsuitable water quality can damage the
boiler body.
Operate boilers only with softened water.
Observe the instructions in chapter "Water
quality requirements". See page 22.
04. Enter the amount of fill water and water hardness
into the water quality table in the appendix on
page 25.
05. Check the system pressure.
06. Check the oil level or the gas supply pressure.
07. Open the flue gas damper (if installed).
08. Check that the cleaning aperture on the flue outlet
is closed.
09. Open the shut-off valves in the oil or gas line.
10. 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.
11. The dew point range must be cleared as quickly
as possible. To do so, prevent any heat supply to
the 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.
12. Once the flow temperature has been reached,
successively switch on the heat consumers.
Switch the burner over to automatic mode.
!Please note
When checking CO levels in the flue gas,
internal outgassing from the thermal block
can result in higher values.
Continue to operate the boiler until a decline
can be clearly recognised.
13. Check all gaskets and plugs, and retighten if nec-
essary.
14. Check the boiler door and cleaning cover after
approx. 50 hours run. Tighten the screws.
Shutting down the system
Danger
Opening the connections on the heating water
side whilst the boiler is under pressure can
result in injuries.
First depressurise the boiler.
Only drain the boiler with a suction pump when
the air vent valve is open.
Closing the Vitoair draught stabiliser (if installed)
1. Start the burner. 2. With the pre-purge running, shut down the system.
The control disk will then be closed.
Opening the boiler door and cleaning cover
Note
On gas burners, disconnect the gas supply pipe.
Commissioning, inspection, maintenance
Commissioning the system
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4x
Fig. 1
Cleaning the internal pipes, heating surface, flue outlet and flue pipe
A C DB
Fig. 2
1. Remove internal pipes B with internal pipe extrac-
tor A.
2. Clean flues C and combustion chamber D with
the brush.
Remove combustion residues with a vacuum
cleaner.
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover (cont.)
5692818

10
E
Fig. 3
3. Remove combustion residues from the flue pipe
and the flue outlet through cleaning aperture E in
the flue outlet using a vacuum cleaner.
Checking all gaskets and packing cords on the flue gas side
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
Checking the thermal insulation components on the boiler door
If work needs to be carried out on the thermal insula-
tion, observe the following:
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre 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.
Commissioning, inspection, maintenance
Cleaning the internal pipes, heating surface,… (cont.)
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A
3
B
C A DE
1 2
Fig. 4
AInsert internal pipes as far as they will go.
BOnly for 500 kW
CHot gas flue
DResistor
ESpring clip
Securing the boiler door and cleaning cover
Note
On gas burners, mount the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for leaks.
Commissioning, inspection, maintenance
Inserting the internal pipes
5692818

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4x
A
Fig. 5
Tighten screws A crosswise (torque 25 Nm).
Checking connections and sensor well on the heating water side for tight-
ness
Checking the function of safety equipment
Check the safety valves, the water level and pressure
limiters in accordance with manufacturer's details.
Checking the function of the pressure switch
Installation instructions, pressure switch set
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation Note
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Securing the boiler door and cleaning cover (cont.)
5692818

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Expansion vessel
1. Drain the system until the pressure gauge indi-
cates "0" or 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 high limit safety cut-
out settings apply
■100 °C: 0.2 bar (0.02 MPa)
■110 °C: 0.7 bar (0.07 MPa).
2. If the pre-charge pressure of the 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 (0.01 to 0.02 MPa) higher.
The static pressure corresponds to the static head.
3. Top up with softened water until the charge pres-
sure of the cooled system is 0.1 to 0.2 bar (0.01 to
0.02 MPa) higher than the pre-charge pressure of
the expansion vessel.
Permiss. operating pressure: 4 bar (0.4 MPa)
For water quality requirements, see page 22.
Pump controlled pressure maintaining systems
!Please note
Pressure fluctuations may cause damage to the
boiler or to other system components.
In heating systems with automatic pressure
maintaining systems, provide individual protec-
tion by installing a diaphragm expansion vessel
for each boiler. This applies in particular to pump
controlled pressure maintaining systems with
integral deaeration.
This reduces the frequency and level of pres-
sure fluctuations. This in turn contributes signifi-
cantly to improved operational reliability and a
longer service life of the system components.
Boiler out-
put
kW Up to 300 Up to 500
Expansion
vessel
l 50 80
!Please note
The ingress of oxygen can result in system dam-
age as a consequence of oxygen corrosion.
Only use pump controlled pressure maintaining
systems that are sealed against corrosion. The
pressure maintaining systems must be protected
against oxygen ingress into the heating water.
Pump controlled pressure maintaining systems
with atmospheric deaeration through cyclical
pressure release bring about central post-venti-
lation of the heating system. They do not pro-
vide oxygen removal in the sense of corrosion
protection as described in VDI 2035 Part 2.
Carry out all checks in accordance with the manufac-
turer's instructions. Limit pressure fluctuations to the
lowest possible differential. Cyclical pressure fluctua-
tions and more significant pressure differentials point
towards a system fault. Immediately remedy such
faults, otherwise other heating system components
may suffer damage.
Checking the setting of the temperature controller if a building management
system is used (DCC system)
!Please note
Shutting down from full load can result in high
material stress and material damage to the
boiler.
If a system with a higher ranking building man-
agement system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller TR to at least 10 K below
the mechanical temperature controller TR of the
Vitotronic.
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
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Checking the thermal insulation
Checking the water quality
Observe the instructions in chapter "Water quality
requirements".
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table in the
appendix on page 25.
The total hardness of the feed and top-up water must
not exceed 0.11 °dH (total value of alkaline earths
≤ 0.02 mol/m3). The pH value should be between 9
and 10.5.
Cleaning the sight glass in the boiler door
Fig. 6
Check the gaskets and hose connection for leaks.
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the mixer han-
dle.
2. Check the mixer for ease of operation.
3. Check the mixer for leaks. Replace the O-rings if
the mixer leaks.
4. Snap the motorised lever into place.
Checking the function of the return temperature raising facility (if
installed)
Checking the installation room ventilation
Commissioning, inspection, maintenance
Checking electrical plug-in connections and cable grommets for firm seat-
ing
5692818

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Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc. The control disc must swing freely during burner oper-
ation.
Adjusting the burner
Burner service instructions or separate docu-
mentation from the burner manufacturer
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
kW Pa mbar
90 40 0.4
115 60 0.6
140 80 0.8
180 100 1.0
235 200 2.0
Rated heating
output
Pressure drop on the hot gas
side
kW Pa mbar
300 200 2.0
390 200 2.0
405 250 2.5
500 330 3.3
To protect the system against dew point corrosion,
burner stage 2 (full heating output) must be set to the
rated boiler heating output. It must remain switched on,
even during the summer months (burner stage 2 on
constant standby).
Partial load operation
Set the minimum heating output for the base load
stage according to the conditions of the flue system.
Note that the flue system must be suitable for the low
flue gas temperatures that may occur.
In the event of frequent cycling in standby mode and
for partial loads below 40 %
■Insulate the flue gas collector.
■Install a motorised flue gas damper.
■Set the minimum runtime for the burner to 10
minutes.
This extends the service life and reduces running
costs.
Operation with burner load ≥ 60 %
The minimum boiler water temperature for oil operation
is 40 °C and for gas operation 50 °C.
To protect the boiler, the minimum heating output at
the base load stage is set to 60 % of rated heating out-
put.
Rated heating output Minimum heating output
to be set (burner stage
1)
kW kW
90 54
115 69
140 84
Rated heating output Minimum heating output
to be set (burner stage
1)
kW kW
180 108
235 141
300 180
390 234
405 243
500 300
Commissioning, inspection, maintenance
Checking the flue pipe for leaks
5692818

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The base load stage requires a minimum flue gas tem-
perature, the value of which is subject to the design of
the flue system.
Operation with burner load ≥ 40 % and < 60 %
The minimum system temperatures (flow/return) are
50/40 °C for oil operation and 60/50 °C for gas opera-
tion.
Operation with burner load < 40 %
The minimum system temperatures (flow/return) are
55/50 °C for oil operation and 65/60 °C for gas opera-
tion.
Instructing the system user
The installer must instruct the user in the operation of
the system.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand the system user this part for safekeeping.
■Retain the heating contractor's part.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation and, therefore, do not need to
be retained.
Commissioning, inspection, maintenance
Adjusting the burner (cont.)
5692818

17
The following details are required when ordering parts:
■Serial no. (see type plate A)
■Position number of the part from this parts list
Parts not shown
Pos. Part
300 Installation instructions
301 Service instructions
302 Thermal insulation, small parts
303 Touch-up spray paint, Vitosilver
304 Touch-up paint stick, Vitosilver
305 Flame tube gasket
Parts list
Ordering parts
5692818
Components

18
B
012
008
009
200
208
207 206
019
020
001
002
010
214214
003
007
006
005
004
022
021
Fig. 7
BBoiler control unit, see parts list in the service
instructions of the boiler control unit
Parts list
Parts list
5692818
Components

19
Pos. Part
001 Boiler door
002 Bolt
003 Parts for sight glass, comprising: Pos. 004 to 007
004 Sight glass frame
005 Gasket
006 Hose nozzle
007 Plastic hose
008 Hose packing Ø 18 mm
009 Thermal insulation block
010 Thermal insulation mat
012 Packing GF 20 x 15 mm
019 Cleaning brush Wearing part
020 Complete cleaning equipment (incl. extraction hook and pos. 019)
021 Burner plate*1
022 Gasket, burner plate*1
200 Front panel, top
206 Top panel, right
207 Top panel, left
208 Control unit fascia
214 Fixing rail, top
*1 from 140 kW
Parts list
Parts list (cont.)
5692818
Components

20
216
216 218204
203
213
213
211
217205
014
014
013
210
202
016 015
017
201215 215
C
C
D
018
209
212
Fig. 8
AType plate, either right or left
CBurner cable, see parts list in the service instruc-
tions of the boiler control unit
DTherm-Control temperature sensor
Parts list
Parts list
5692818
Components