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
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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.)
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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
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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
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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.)
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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
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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.)
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4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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.)
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Inserting the internal pipes
A
3
B
C A DE
1 2
AInsert internal pipes as far as they
will go
BOnly for 500 kW
CHot gas flue
DEnd stop
ESpring clip
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Securing the boiler door and cleaning cover
Note
On systems with gas burners, fit the gas
supply pipe.
Danger
Escaping gas leads to a risk of
explosion.
Test the tightness of all gas con-
nections.
4x
A
ATighten the screws diagonally.
Checking the function of the safety equipment
Check the safety valves, the water level
and pressure limiters in accordance with
manufacturer's details.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the diaphragm expansion vessel and system pressure
Note
Observe the details provided by the
manufacturer of the diaphragm expan-
sion vessel.
Perform this test on a cold system.
Diaphragm expansion vessel
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.
Note
The pre-charge pressure of the dia-
phragm expansion vessel (p0) com-
prises the static system pressure
(pSt) (= static head) and a supplement
(p0 = pSt + supplement).
The supplement is subject to the
adjustment of the high limit safety cut-
out. It is as follows for a high limit
safety cut-out set to:
■ 100 °C: 0.2 bar
■ 110 °C: 0.7 bar
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 raised by 0.1 to 0.2 bar.
The static pressure corresponds to
the static head.
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: 4 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Pump controlled pressure maintaining systems
!Please note
Pressure fluctuations may cause
damage to the boiler or to other
system components.
In heating systems with auto-
matic pressure maintaining sys-
tems, and in particular pump con-
trolled systems with integral dea-
eration, we recommend the
installation of a diaphragm
expansion vessel (DEV) as indi-
vidual boiler protection.
This reduces the frequency and
level of pressure fluctuations.
This contributes considerably to
improved operational reliability
and longer service life of the sys-
tem components.
Boiler output kW up to 300 up to 500
Diaphragm expansion vessel capacity litres 50 80
!Please note
The ingress of oxygen can result
in system damage as a conse-
quence of oxygen corrosion.
Ensure that only pump controlled
pressure maintaining systems
that are sealed against corrosion
and protected against oxygen
ingress into the heating water are
used.
Pump controlled pressure main-
taining systems with atmospheric
deaeration through cyclical pres-
sure release create a central
post-venting of the heating sys-
tem. However, this does not rep-
resent oxygen removal in the
sense of corrosion protection to
VDI 2035 sheet 2.
Carry out all checks in accordance with
the manufacturer's instructions. Limit
pressure fluctuations to the lowest pos-
sible differential. Cyclical pressure fluc-
tuations and more significant pressure
differentials point towards a system fault.
Immediately remedy such faults, other-
wise other heating system components
may become faulty.
Checking the water quality
Observe the instructions in chapter "Water quality requirements".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Enter the volume of the top-up water and the total hardness of the feed and boiler
water into the table.
Meter
reading
Fill and
top-up
water
Total
water
volume
Total hardness pH
value
Water treat-
ment
Date
Feed-
water
Boiler
water
Me-
dium
Meter-
ing vol-
ume
m3m3m3°dH °dH
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the sight glass in the boiler door
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 handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-rings if the mixer leaks.
4. Snap the motorised lever into place.
Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc. The control disc must swing freely during
burner operation.
Adjusting the burner
Burner service instructions or
separate documentation from the
burner manufacturer.
Adjust the maximum oil or gas through-
put of the burner to the rated boiler out-
put.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Rated out-
put
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
300 200 2.0
390 200 2.0
500 330 3.3
To protect the system against dew point
corrosion, burner stage 2 (full capacity)
must be set to the rated boiler output and
must not be switched off during summer-
time (burner stage 2 on constant
standby).
Operation with burner load ≥ 60 %
The minimum boiler water temperature
for operation with oil is 40 °C and for gas
50 °C.
To protect the boiler, the minimum output
in the base load stage is set to 60 % of
the rated output.
Rated output Minimum output to be
selected (burner stage
1)
kW kW
90 54
115 69
140 84
180 108
235 141
300 180
390 234
500 300
A minimum flue gas temperature is
required for the base load stage, the
value of which is subject to the design of
the flue system.
Operation with partial load
Set the minimum 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 tem-
peratures that may occur.
It is recommended that the flue gas col-
lector is thermally insulated, a motorised
flue gas damper is installed and the min-
imum boiler runtime is set to 10 minutes
if the boiler cycles frequently in standby
mode and for partial loads below 40 %.
This extends the service life and reduces
the running costs.
Operation with burner loads ≥ 40 %
and < 60 %
For oil operation, the minimum system
temperatures (flow/return) are 50/40 °C
and for gas operation 60/50 °C.
Operation with burner load < 40 %
For oil operation, the minimum system
temperatures (flow/return) are 55/50 °C
and for gas operation 65/60 °C.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 serv-
ice instructions 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
Further details regarding the individual steps (cont.)
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Spare parts information
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.
Parts
001 Boiler door
002 Stud
003 Sight glass pack, comprising:
Pos. 004 to 007
004 Sight glass frame pack
005 Gasket
006 Hose ferrule
007 Plastic hose
008 Hose pack Ø 18 mm
009 Thermal insulation block
010 Thermal insulation mat
012 Packing GF 20 x 15 mm
013 Internal pipe
014 Gasket
015 Cleaning cover
016 Packing
017 Sensor well, boiler water tempera-
ture sensor
018 Sensor well, Therm-Control
200 Front panel, top
201 Front panel, bottom
202 Back panel, top
203 Back panel, bottom
204 R.h. side panel, front
205 L.h. side panel, front
206 R.h. top panel
207 L.h. top panel
208 Control unit fascia
209 Thermal insulation jacket
210 Thermal insulation mat, back
211 Thermal insulation mat, flue gas
collector
212 Logo
213 Edge protection
214 Top fixing bracket
215 Bottom fixing bracket
216 Central side panel (only from
390 kW)
217 R.h. side panel, back
218 L.h. side panel, back
Parts not shown
300 Installation instructions
301 Service instructions
302 Thermal insulation pack
303 Spray paint, Vitosilver
304 Touch-up paint stick, Vitosilver
305 Flame tube sealing pack
Wearing part
019 Cleaning brush
Accessories
020 Cleaning equipment complete (incl.
extraction hook and pos. 019)
021 Burner plate pack*1
022 Burner plate gasket*1
AType plate, optionally left or right
BBoiler control unit, see parts list in
the service instructions of the boiler
control unit
CBurner cable, see parts list in the
service instructions of the boiler
control unit
DTherm-Control temperature sensor
*1 from 140 kW
Parts list
Parts list
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B
012
008
009
212
200
208
207 206
019
020
001
002
010
214214
003
007
006
005
004
022
021
Parts list
Parts list (cont.)
5692 818 GB