Viessmann VITORADIAL 300-T Type VR3 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoradial 300-T
Type VR3, 101 to 335 kW
Condensing boiler with heat exchanger
VITORADIAL 300-T
5692820 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
5692820

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.)
5692820

4
1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Parts lists Ordering parts ........................................................................................ 21
Boiler part 1 ........................................................................................... 22
Boiler part 2 ........................................................................................... 24
Heat exchanger ..................................................................................... 26
Heat exchanger insulation and casing ................................................... 28
4. Water quality Water quality requirements .................................................................... 30
■Prevention of damage due to scaling ................................................. 30
■Prevention of damage due to corrosion on the water side ................. 31
5. Commissioning/service
reports
Water quality .......................................................................................... 32
Maintenance/service .............................................................................. 32
6. Specification ................................................................................................................ 34
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 35
8. Certificates EU Declaration of Conformity ................................................................ 36
Manufacturer's certificate ....................................................................... 36
9. Keyword index ................................................................................................................ 37
Index
Index
5692820

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
5692820
Information

6
Vitoradial 300-T, type VR3
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 4 bar (0.4 MPa)
■Rated heating output 111 to 335 kW
Information
Product information
5692820
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Settings at the boiler control unit..................................................................................... 8
•2. Checking the connections of the neutralising system and filling with neutralising
agent
••• 3. Commissioning the system............................................................................................... 8
•4. Checking the burner adjustment...................................................................................... 8
• • 5. Shutting down the system................................................................................................. 9
• • 6. Opening the boiler door..................................................................................................... 9
•7. Cleaning the internal pipes and heating surface............................................................ 10
••• 8. Checking the gaskets and packing cords on the flue gas side
• • 9. Checking the thermal insulation components on the boiler door................................. 10
•10. Inserting the internal pipes............................................................................................... 11
• • 11. Fitting the boiler door........................................................................................................ 11
••• 12. Checking connections and sensor well on the heating water side for tightness
••• 13. Checking the function of the safety equipment.............................................................. 12
••• 14. Checking the function of the pressure switch................................................................ 12
••• 15. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 12
••• 16. Checking the expansion vessel and system pressure................................................... 12
••• 17. Checking the firm seating of electrical plug-in connections and cable grommets
••• 18. Checking the heat exchanger gasket............................................................................... 14
• • 19. Cleaning the flue outlet and heat exchanger................................................................... 17
• • 20. Checking the water quality................................................................................................ 17
• • 21. Checking the neutralising system according to the manufacturer's instructions;
replacing used agent
• • 22. Cleaning the sight glass in the boiler door...................................................................... 18
••• 23. Checking the mixer for ease of operation and tightness............................................... 18
••• 24. Checking the function of the return temperature raising facility (if installed)
••• 25. Checking the installation room ventilation
••• 26. Checking the flue pipe and all connections from the heat exchanger to the flue
system for tightness
• • 27. Restarting the system
• • 28. Adjusting the burner.......................................................................................................... 19
•29. Instructing the system user.............................................................................................. 20
•30. Operating and service documents................................................................................... 20
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692820

8
Make the settings according to the information in chap-
ter "Additional information, coding" in the control unit
service instructions.
Checking the connections of the neutralising system and filling with
neutralising agent
Commissioning the system
Operating and service instructions for the control
unit and the burner
01. Open the boiler door and check that the internal
pipes are fully inserted into the hot gas flues. See
chapter "Inserting the internal pipes".
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
Scaling may result if the system is not oper-
ated with fully softened heating water. Oper-
ate boilers only with softened water.
Observe the instructions in chapter "Water
quality requirements".
04. Enter the amount of fill water and water hardness
into the "Water quality" table in the appendix.
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. After the flow temperature has been reached,
switch ON the heat consumers 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 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.
Torque for boiler door 25 Nm; for cleaning cover
5 Nm
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.
Checking the burner adjustment
Burner service instructions
Commissioning, inspection, maintenance
Settings at the boiler control unit
5692820

9
Danger
There is a risk of injury when working on pres-
surised components.
Only open the connections on the heating water
side after the boiler has been depressurised.
Only drain the boiler with a suction pump when
the air vent valve is open.
Opening the boiler door
4x
Fig. 1
Commissioning, inspection, maintenance
Shutting down the system
5692820

10
A C DB
Fig. 2
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.
3. Remove combustion residues from the flue pipe
and the flue outlet through the cleaning aperture in
the flue outlet using a vacuum cleaner. See
page 17
4. Tighten cleaning cover to 5 Nm.
Checking the gaskets and packing cords on the flue gas side
Checking the thermal insulation components on the boiler door
Danger
Fibre dust can be produced if working with high
temperature insulation materials that contain zir-
conium or aluminium silicate ceramic fibres. 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 and heating surface
5692820

11
A
Fig. 3
AInsert internal pipes as far as they will go.
Fitting the boiler door
4x
A
Fig. 4
AClose the door: Tighten screws crosswise to
25 Nm.
Commissioning, inspection, maintenance
Inserting the internal pipes
5692820

12
Danger
Escaping gas leads to a risk of explosion.
Check the boiler door for tightness.
Checking connections and sensor well on the heating water side for tight-
ness
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 function of the pressure switch
Installation instructions, pressure switch set
Checking the temperature controller setting 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.
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 to at least 10 K below the
mechanical temperature controller.
Checking the expansion vessel and system pressure
Note
Observe the information provided by the expansion
vessel manufacturer.
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Fitting the boiler door (cont.)
5692820

13
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 (20 kPa)
■110 °C: 0.7 bar (70 kPa)
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 (10 to 20 kPa) 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 (10 to
20 kPa) higher than the pre-charge pressure of the
expansion vessel.
Permiss. operating pressure: 4 bar (0.4 MPa)
Note
Observe chapter "Water quality requirements".
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, and in particular pump
controlled systems with integral deaeration, we
recommend the installation of a diaphragm
expansion vessel (DEV) as individual boiler pro-
tection.
This reduces the frequency and level of pres-
sure fluctuations. This contributes considerably
to improved operational reliability and a longer
service life of the system components.
Boiler heating out-
put
kW up to
300
up to
500
up to
1000
Expansion vessel
capacity
l 50 80 140
!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-ventilation of the heat-
ing system. They do not provide 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 sys-
tem faults, otherwise other heating system compo-
nents may suffer damage.
Checking the firm seating of electrical plug-in connections and cable
grommets
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
5692820

14
Removing the cover panel
4,8 x 9,5
Fig. 5
ACover plate
Commissioning, inspection, maintenance
Checking the heat exchanger gasket
5692820

15
Removing the top panels
Fig. 6
Removing the back panel
3,9 x 9,5
Fig. 7
ABack panel
Commissioning, inspection, maintenance
Checking the heat exchanger gasket (cont.)
5692820

16
Removing the heat exchanger cover
Fig. 8
1. Cut open the fabric lining on the cover at lower per-
foration A (outer ring).
2. Remove cut-out fabric lining D.
3. Remove heat exchanger cover C by undoing the
4 hexagon screws.
4. Remove gasket B and clean the sealing face.
Assembly
Assemble in reverse order.
Tighten cleaning cover to 5 Nm.
Commissioning, inspection, maintenance
Checking the heat exchanger gasket (cont.)
5692820

17
A
B
C
D
Fig. 9
1. Remove condensate hose and stench trap from
the heat exchanger.
2. Push on-site hoses C onto condensate drains and
route into a suitable container D.
3. Vacuum up combustion residues from the flue
pipe, flue gas collector and heat exchanger
through cleaning apertures A and B.
!Please note
Contact with unalloyed iron and scratches
on parts in contact with flue gases can lead
to corrosion.
Only use plastic brushes, not wire brushes
or sharp objects.
4. Coat the heat exchanger coil with cleaning agent
(e.g. Fauch 400/410) through cleaning aperture A
and proceed in accordance with the cleaning agent
manufacturer's instructions.
5. Before installation, check the stench trap and con-
densate drain for contamination and clean if
required.
Danger
Escaping flue gas poses a risk to health.
Always connect the condensate drain with a
stench trap to prevent flue gas escaping.
Neutralising system installation and operating
instructions
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 32.
The total hardness of the feed and top-up water must
not exceed a sum of all alkaline earths of ≤
0.02 mol/m3.
The pH value should be between 8.2 and 9.5.
Checking the neutralising system according to the manufacturer's
instructions; replacing used agent
Commissioning, inspection, maintenance
Cleaning the flue outlet and heat exchanger
5692820

18
Fig. 10
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
Checking the flue pipe and all connections from the heat exchanger to the
flue system for tightness
Restarting the system
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door
5692820

19
Burner service instructions or separate docu-
mentation by the burner manufacturer
Adjust the maximum oil throughput of the burner to the
rated boiler heating output.
Rated combus-
tion heating out-
put Qn
Pressure drop on the hot gas
side
kW Pa mbar
97 55 0.55
124 80 0.80
151 120 1.20
Rated combus-
tion heating out-
put Qn
Pressure drop on the hot gas
side
kW Pa mbar
194 180 1.80
254 240 2.40
323 275 2.75
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 case of frequent cycling in standby mode and for
partial loads below 40 % we recommend the following:
■Insulate the flue gas collector.
■Install a motorised flue gas damper.
■Set the minimum runtime for the boiler 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.
To protect the boiler, the minimum heating output at
the base load stage is set to 60 % of rated heating out-
put.
Rated combustion
heating output Qn
Minimum heating output to
be set (burner stage 1)
kW kW
97 58
124 74
151 91
194 116
254 152
323 194
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
50/35 °C for oil operation and 60/45 °C for gas opera-
tion.
Commissioning, inspection, maintenance
Adjusting the burner
5692820

20
Operation with burner load < 40 %
The minimum system temperatures (flow/return) are
55/45 °C for oil operation and 65/55 °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.)
5692820