Viessmann VITOPLEX 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoplex 300
Type TX3A
Oil/gas fired boiler
Rated output 620 to 2000 kW
VITOPLEX 300
5692 798 2/2009 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
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
electrician.
■ The system must be commissioned by
the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the
prevention of accidents,
■ all legal instructions regarding
environmental 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)
Regulations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern
Ireland),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring
Regulations.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
■ Never 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the
building.
■ 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-
threatening 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
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static
discharges.
Touch earthed objects, such as
heating or water pipes, to
discharge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can
compromise 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
compromise its function.
Installing non-authorised
components and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only
original 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 lists............................................................................................................ 17
Water quality requirements............................................................................... 22
Commissioning/service reports........................................................................ 25
Specification....................................................................................................... 26
Declaration of Conformity
Declaration of conformity...................................................................................... 27
Manufacturer's certificate
Manufacturer’s certificate according to the 1st BImSchV..................................... 28
Keyword index.................................................................................................... 29
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............................................. 8
•3. Opening the boiler door and clean-out cover.............. 9
•4. Cleaning the internal pipes, heating surface, flue
outlet and flue pipe......................................................... 10
• • 5. Checking all seals/gaskets and packing cords on the
flue gas side
• • 6. Checking the thermal insulation of the boiler door
•7. Inserting the internal pipes, fitting the boiler door and
clean-out cover............................................................... 11
• • 8. Checking connections and sensor well for leaks on
heating water side
• • 9. Checking the function of the safety equipment........... 12
• • 10. Checking the diaphragm expansion vessel and
system pressure............................................................. 12
• • 11. Checking the tightness of electrical plug-in
connectors and cable grommets
• • 12. Checking the thermal insulation
• • 13. Checking the water quality............................................ 14
• • 14. Cleaning the sight glass in the boiler door.................. 15
•15. Checking the mixer for ease of operation and leaks... 15
•16. Checking the function of the return temperature
raising facility (if installed)
• • 17. Checking the installation room ventilation
• • 18. Checking the flue pipe for tightness
•19. Adjusting the burner...................................................... 15
•20. Instructing the system user........................................... 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•21. Operating and service documents................................ 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Commissioning the system
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 that internal pipes C are
pushed into hot gas flues B so that
safety spring D snaps into place
behind the first resistance E.
AInternal pipe extractor
03. Check that the installation room
ventilation aperture is open.
04. Fill the heating system with water
and ventilate the system.
Permissible operating pressure:
6 bar
!Please note
Unsuitable water qualities
can result in boiler body
damage.
According to VDI Directive
2035, the heating system
must be filled and operated
with water in which the sum
of alkaline earths must not
exceed 0.02 mol/m3.
Observe the "Water quality
requirements" on
page 22.
Note
Record the fill volume and water
hardness on page 14.
05. Check the system pressure.
06. Check the fuel 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 gas or oil line shut-off
valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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10. Switch ON the main isolator, the
switch for the heating circuit pump
and the burner ON/OFF switch in
the order listed here (observe the
burner manufacturer's
instructions).
11. When heating the system from cold
(also when restarting after
maintenance and cleaning work),
prevent all heat transfer to
consumers, to clear the dew point
range as quickly as possible.
12. After the flow temperature has been
reached, switch ON the heat
consumers in sequence and
change the burner over to automatic
mode.
13. Check all gaskets/seals and plugs,
and retighten if necessary.
14. Check the boiler door and clean-out
cover after approx. 50 hours and
retighten all screws.
!Please note
During boiler heat-up, unpleasant
fumes and odours can result from
gases being expelled from the
thermal insulation, the heating
block and the paint.
Vent the room during
commissioning.
!Please note
When testing the flue gas for CO,
internal gases being expelled
from the heating block can cause
higher values.
Continue to operate the boiler
until a decline can be clearly
recognised.
Shutting down the system
1. Switch OFF the main isolator or the
power supply, and safeguard against
unauthorised reconnection.
2. Interrupt the burner power supply.
For this, pull the power supply plug-in
connectors fA and lÖ (if installed)
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.
!Please note
Draining the boiler with a suction
pump will create negative
pressure inside the boiler.
Drain the boiler with a suction
pump only when the air vent
valve has been cracked open.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Opening the boiler door and clean-out cover
Note
In case of gas burners, remove the gas supply pipe.
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
pipe
1. Remove internal pipes B with a
quick tug towards the front; for this,
use internal pipe extractor A, which
is part of the cleaning equipment.
2. Clean flues C and combustion
chamber D with the brush.
Remove combustion residues with a
vacuum cleaner.
3. Remove combustion residues from
the flue and the flue outlet through the
clean-out 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, fitting the boiler door and clean-out
cover
Note
Fit the gas supply pipe in case of gas burners.
Danger
Escaping gas leads to a risk of explosion.
Test the tightness of all gas connections.
4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Push internal pipes C far enough into
hot gas flues B that safety spring E
snaps into place behind the first
resistance D.
Tighten screws A diagonally.
Note
This snapping into place prevents the
internal pipes from slipping forward
during boiler operation.
Checking the function of the safety equipment
Check the safety valves, the water level
and pressure limiters in accordance with
manufacturer's details.
Checking the diaphragm expansion vessel and system pressure
Observe the manufacturer's documentation regarding the diaphragm
expansion vessel.
Note
Carry out this test on a cold system.
Pump-controlled pressure
maintaining systems
In heating systems with automatic
pressure maintaining systems, and in
particular pump-controlled systems, with
integral degassing, we recommend the
installation of a diaphragm expansion
vessel (DEV) as individual boiler
protection.
Boiler
output
kW up to
1000
up to
2000
DEV litres 140 300
This reduces the frequency and level of
pressure fluctuations. This contributes
considerably to improved operational
reliability and a longer service life of the
system components. Damage to the
boiler or to other system components
may result if these recommendations are
not followed.
Furthermore ensure that only pump-
controlled pressure maintaining systems
that are sealed against corrosion and
protected against oxygen ingress into
the heating water are used. Otherwise
damage to the system through oxygen
corrosion can result.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Pump-controlled pressure maintaining
systems with atmospheric degassing
through cyclical pressure release create
a central post-venting of the heating
system. However, this does not
represent oxygen removal in the sense
of corrosion protection according to VDI
2035 sheet 2.
Note
Carry out all checks in accordance with
manufacturer's instructions.
!Please note
Cyclical pressure fluctuations
and more significant pressure
differentials point towards a
system fault. Such faults will
result in damage to other heating
system components.
Limit pressure fluctuations to the
lowest possible differential.
Diaphragm expansion vessel
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure, until
the pressure gauge indicates "0".
Note
The pre-charge pressure of the
diaphragm expansion vessel (p0)
comprises 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. 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
diaphragm expansion vessel is lower
than the static system pressure, top
up with sufficient nitrogen to raise the
pre-charge pressure higher (0.1 to
0.2 bar) than the static system
pressure.
The static pressure corresponds to
the static head.
3. Top up the heating system until the
filling pressure of the cool system is
higher (0.1 to 0.2 bar) than the pre-
charge pressure of the diaphragm
expansion vessel.
Permiss. operating pressure: 6 bar.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the water quality
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
Date
Feedwa
ter
Boiler
water
m3m3m3°mmol/l °mmol/l
The total hardness of the feed and top-up water must not exceed 0.02 mmol/l.
The pH value should be between 8.2 and 9.5.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the sight glass in the boiler door
Note
Check the gaskets and hose connection
for leaks.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the
mixer handle.
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.
Adjusting the burner
Adjust the maximum oil or gas
throughput of the burner to the rated
boiler output.
Rated output Hot gas pressure
drop
kW Pa mbar
620 350 3.5
780 400 4.0
Rated output Hot gas pressure
drop
kW Pa mbar
1000 400 4.0
1250 500 5.0
1600 850 8.5
2000 800 8.0
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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To protect the system against dew point
corrosion, the 2nd burner stage (full
capacity) must be set to the rated boiler
output and must not be switched OFF
during summer time (stage 2 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 (see table).
Rated output Minimum output to be
selected (burner stage
1)
kW kW
620 372
780 468
1000 600
1250 750
1600 960
2000 1200
A minimum flue gas temperature is
required for the base load stage, the
value of which is subject to the design of
the flue gas system.
Operation with burner load < 60 %
The minimum boiler water temperature
for operation with oil is 50 °C and for gas
60 °C.
Set the minimum heating output for the
base load stage according to the
conditions of the flue gas system. Note
that the flue gas system must be suitable
for the low flue gas temperatures that
may occur.
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 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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Information regarding the ordering of
spare parts
Quote the part and serial no. (see type
plate) and the item no. 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 Upper insulation block
010 Lower insulation block
011 Thermal insulation mat
012 Packing GF 25 × 15
013 Internal pipe
014 Gasket, flow/return
015 Gasket, safety valve
016 Clean-out cover
017 Packing
018 Sensor well, boiler water
temperature sensor
019 Sensor well, Therm-Control
temperature sensor
200 Cover panel, front
201 Cover panel, back
202 Top front panel (only for 1600 to
2000 kW)
203 Top front and back panel
204 Bottom front panel
205 Back panel, bottom
206 Side panel
207 Side panel, control unit
208 Centre rail
209 Front r.h. rail
210 Front l.h. rail
211 Back r.h. rail
212 Back l.h. rail
213 Thermal insulation jacket
214 Thermal insulation jacket, centre
(only for 1000 to 2000 kW)
215 Thermal insulation mat, back
216 Insulation mat, l.h. back
217 Insulation mat, r.h. back
218 Mounting panel, back
219 Mounting panel
220 Channel retainer
221 Top part, cable duct
222 Bottom part, cable duct
223 Edge protector
224 Cover, sensor coupling
225 Front insulation mat
226 Insulation mat, l.h. front
227 Insulation mat, r.h. front
Wearing part
020 Cleaning brush
Accessories
021 Cleaning equipment complete (incl.
extraction hook and pos. 20)
022 Burner plate pack
023 Burner plate gasket*1
Parts not shown
300 Thermal insulation pack
301 Touch-up spray, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
305 Decorative adhesive tape
*1 for sizes 620 and 780 kW with seal ring,
for sizes 1000 and 2000 kW with glass fibre-reinforced fabric ribbon
Parts lists
Parts lists
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AType plate, optionally on the r.h. or
l.h. side
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
011 012
008009001
005
004
006
007
022
023
003
012
Parts lists
Parts lists (cont.)
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201
204 225
213
214
213
227
226
200
200
202
203
212
210
208
206
206
201
206
206
Parts lists
Parts lists (cont.)
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206 221219
223
218
203
205
217
216
215
206
211
209
207
206
208
B
222
220
A
Parts lists
Parts lists (cont.)
5692 798