Viessmann VITORADIAL 300-T 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 4/2021 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 per-
son 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
■Relevant country-specific safety regu-
lations
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 safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, 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 recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
5692820

3
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 pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692820

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not 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.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply 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 spread-
ing.
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 condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion 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-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
5692820

5
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 suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692820

6
1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
System examples .................................................................................. 8
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
3. Fuel oil Ordering heating oil ............................................................................... 22
■Fuel oil additives ................................................................................. 22
■Combustion improvers ........................................................................ 22
■Biofuels ............................................................................................... 22
4. Water quality Water quality requirements .................................................................... 23
■Prevention of damage due to scaling ................................................. 23
■Prevention of damage due to corrosion on the water side ................. 24
5. Commissioning/service
reports
Water quality .......................................................................................... 25
Maintenance/service .............................................................................. 25
6. Specification ................................................................................................................ 27
7. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 28
8. Certificates EU Declaration of Conformity ................................................................ 29
Manufacturer's certificate ....................................................................... 29
9. Keyword index ................................................................................................................ 30
Index
Index
5692820

7
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

8
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
System examples
Available system examples: See
www.viessmann-schemes.com.
Information
Product information
5692820
Information

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

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Make the settings according to the information in chap-
ter "Additional information, coding" in the control unit
service instructions.
To keep the burner cycle ratio as low as possible, set a
variable switching hysteresis.
Check the connections to the neutralising system. Filling with neutralising
agent
Top up the neutralising system with water as neces-
sary. If the neutralising system is found to have dried
out, optimise the system hydraulics to improve its con-
densation properties. Increase the number of mainte-
nance intervals for the neutralising system.
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 and boiler damage may result if the
system is not operated with fully softened
heating water. Operate 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 table in chapter "Checking the water qual-
ity".
05. Check the system pressure.
06. Check the oil level or the gas supply pressure.
07. Open the flue gas gate valve or flue gas damper
(if installed).
08. Check that the cleaning aperture on the flue outlet
is closed.
Danger
Escaping flue gas poses a risk to health.
To prevent flue gas from escaping, always
connect the condensate drain with a trap.
Neutralising system installation and operat-
ing instructions
Note
The trap must always be filled with water. Check
the fill level on commissioning and during mainte-
nance.
Check regularly as there is a risk of the siphon
drying out in non-condensing operation.
09. Open the shut-off valves in the oil or gas line.
10. Start up in the following order
1. Mains isolator
2. Switch for the heating circuit pump
3. ON/OFF switch for the burner
Observe the burner manufacturer'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
When the boiler is heating up, unpleasant
fumes and odours can result from outgas-
sing from the thermal insulation, the thermal
block and the paint.
Ventilate the room during commissioning.
Commissioning, inspection, maintenance
Settings at the boiler control unit
5692820

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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 tighten if neces-
sary.
14. Check the boiler door and cleaning cover after
approx. 50 hours run. Tighten the screws.
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
Shutting down the system
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.
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5692820

12
4x
Fig. 1
Cleaning the internal pipes and heating surface
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 18
Commissioning, inspection, maintenance
Opening the boiler door
5692820

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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.
Inserting the internal pipes
A
Fig. 3
AInsert internal pipes as far as they will go.
Commissioning, inspection, maintenance
Checking the gaskets and packing cords on the flue gas side
5692820

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4x
A
Fig. 4
AClose the door: Tighten screws crosswise to
25 Nm.
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, water level limiter and pres-
sure limiters in accordance with manufacturer's instruc-
tions.
Checking the function of the pressure switch
Installation instructions in the "pressure switch
set"
Note
The boiler must be operated only with a correctly con-
nected and adjusted pressure switch.
Commissioning, inspection, maintenance
Fitting the boiler door
5692820

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!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.
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.
Commissioning, inspection, maintenance
Checking the temperature controller setting if a building management system
is used (DCC system)
5692820

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Checking the heat exchanger gasket
Removing the cover panel
4,8 x 9,5
Fig. 5
ACover plate
Commissioning, inspection, maintenance
Checking the firm seating of electrical plug-in connections and cable
grommets
5692820

17
Removing the top panels
Fig. 6
Removing the back panel
3,9 x 9,5
A
Fig. 7
ABack panel
Removing the heat exchanger cover
Fig. 8
1. Cut fabric lining A around the return pipe.
Commissioning, inspection, maintenance
Checking the heat exchanger gasket (cont.)
5692820

18
2. Remove retaining springs D. Remove fabric lin-
ing.
3. Remove heat exchanger cover C by undoing the
4 hexagon nuts.
4. Remove gasket B and clean the sealing face.
Assembly
Assemble in reverse order.
Tighten cleaning cover to 5 Nm.
Cleaning the flue outlet and heat exchanger
A
B
C
D
Fig. 9
Note
Before and after cleaning the flue draught and heating
surfaces, determine the pressure drop on the hot gas
side; see chapter "Adjusting the burner". If dirt has
caused the pressure drop on the hot gas side to
increase by more than 30 % since the last time it was
cleaned, shorten the cleaning interval. After cleaning,
check the burner adjustment once again in accordance
with the chapter "Adjusting the burner".
1. Remove condensate hose and stench trap from
the heat exchanger.
2. Attach hoses C (provided on-site) to the conden-
sate drain. Route into appropriate container D.
3. Vacuum up combustion residues in 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
through cleaning aperture A. Then proceed in
accordance with the cleaning agent manufacturer's
instructions. Use cleaning agents such as Biocircle
or Sotin smoke resin removers.
If heavily contaminated, use a high pressure clean-
ing device and Sotin combustion chamber cleaning
kit WTF1 with a special rotary nozzle and cleaning
agent.
5. Before installation, check the stench trap and con-
densate drain for contamination and clean if
required. Fill the trap with water.
Note
If the trap is found to have dried out, optimise the
system hydraulics to improve its condensation
properties. Increase the number of maintenance
intervals for the trap.
Danger
Escaping flue gas poses a risk to health.
To prevent flue gas from escaping, always
connect the condensate drain with a trap.
Neutralising system installation and operating
instructions
Commissioning, inspection, maintenance
Checking the heat exchanger gasket (cont.)
5692820

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Observe the instructions in chapter "Water quality
requirements" on page 23.
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 pH value should be between 8.2 and 9.5.
Checking the neutralising system according to the manufacturer's
instructions; replacing used agent
Cleaning the sight glass in the boiler door
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.
Return temperature raising facility
Do not use a return temperature raising facility
(RTRF). An RTRF will inhibit the condensation proc-
ess.
To protect the boiler, use the Therm-Control function
on the control unit.
Checking the installation room ventilation
Checking the flue pipe and all connections from the heat exchanger to the
flue system for tightness
Check the connection between the boiler and the heat
exchanger for tightness.
Commissioning, inspection, maintenance
Checking the water quality
5692820

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Adjusting the burner
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.
Determining the pressure drop on the hot gas side
Determine the pressure drop on the hot gas side
before and after cleaning. See chapter "Cleaning the
flue outlet and heat exchanger".
At full load, measure the pressure difference between
the test connector on the inspection nipple and the flue
draught. After correct cleaning, the pressure drop on
the hot gas side should approximately correspond to
the specified values.
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
Rated combus-
tion heating out-
put Qn
Pressure drop on the hot gas
side
kW Pa mbar
151 120 1.20
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.
Commissioning, inspection, maintenance
Restarting the system
5692820