Viessmann VITOPLEX 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 300
Type TX3A, 90 to 500 kW
Oil/gas boilers
For applicability, see the last page
VITOPLEX 300
5692 818 GB 5/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ 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
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 818 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 818 GB

4
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Parts list.............................................................................................................. 19
Water quality
Water quality requirements.................................................................................. 22
Using antifreeze in boilers.................................................................................... 25
Commissioning/service reports........................................................................ 27
Specification....................................................................................................... 28
Certificates
Declaration of conformity...................................................................................... 29
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 30
Keyword index.................................................................................................... 31
Index
Index
5692 818 GB

5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system........................................... 7
• • 2. Shutting down the system
• • 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................................................................. 10
••• 6. Checking all gaskets and packing cords on the flue
gas side
• • 7. Checking the thermal insulation parts of the boiler
door
•8. Inserting the internal pipes............................................ 11
• • 9. Securing the boiler door and cleaning cover............... 12
••• 10. Checking connections and sensor well for leaks on
the heating water side
••• 11. Checking the function of the safety equipment........... 12
••• 12. Checking the diaphragm expansion vessel and
system pressure............................................................. 13
••• 13. Checking the firm seating of electrical plug-in
connections and cable grommets
••• 14. Checking the thermal insulation
• • 15. Checking the water quality............................................ 14
• • 16. Cleaning the sight glass in the boiler door.................. 16
••• 17. Checking the mixer for ease of operation and
tightness.......................................................................... 16
••• 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
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
5692 818 GB

6
Commissioning steps
Inspection steps
Maintenance steps Page
• • 21. Checking the Vitoair draught stabiliser (if installed)... 16
• • 22. Adjusting the burner...................................................... 16
•23. Instructing the system user........................................... 18
•24. Operating and service documents................................ 18
Commissioning, inspection, maintenance
Steps – commissioning, inspection and… (cont.)
5692 818 GB

7
Commissioning the system
Operating and service instruc-
tions for the control unit and the
burner
01. Check that the internal pipes are
fully pushed into the hot gas flues
(see chapter "Inserting the internal
pipes"); open the boiler door for
this.
02. Check that the installation room
vent is open.
03. Fill the heating system with water
and vent the system.
Permissible operating pressure:
4 bar
04. Record the fill volume and water
hardness (see chapter "Checking
the water quality").
!Please note
Scaling may result if the sys-
tem is not operated with fully
softened heating water.
Observe the instructions in
chapter "Water quality
requirements".
05. Check the system pressure.
06. Check the oil level or the gas supply
pressure.
07. Open the flue gas damper (if instal-
led).
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
this order (observe the burner man-
ufacturer's instructions).
11. When heating the system from cold
(also when restarting after mainte-
nance and cleaning work), prevent
any heat supply to the heat consum-
ers in order to clear the dew point
range as quickly as possible.
!Please note
During boiler heat-up,
unpleasant fumes and
odours can result from gases
being expelled from the ther-
mal insulation, the heating
block and the paint.
Vent the room during com-
missioning.
12. After the flow temperature has been
reached, switch ON the heat con-
sumers in sequence and change the
burner over to automatic mode.
!Please note
When testing the flue gas for
CO, internal gases being
expelled from the heating
block can cause higher val-
ues.
Continue to operate the
boiler until a decline can be
clearly recognised.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 818 GB

8
13. Check all gaskets and plugs, and
retighten if necessary.
14. Check the boiler door and cleaning
cover after approx. 50 hours run and
retighten all screws.
Danger
Opening the connections on the
heating water side whilst the
boiler is under pressure can
result in injuries.
First depressurise the boiler.
Drain the boiler with a suction
pump only when the air vent
valve has been opened.
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 systems with gas burners, remove
the gas supply pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 818 GB

9
4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 818 GB

10
Cleaning the internal pipes, heating surface, flue outlet and flue
A C DB
1. Remove internal pipes B using
internal pipe extractor A.
2. Clean flues C and combustion
chamber D with the brush.
Remove combustion residues with a
vacuum cleaner.
E
3. Remove combustion residues from
the flue and the flue outlet through the
cleaning aperture in flue outlet E
using a vacuum cleaner.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 818 GB