Viessmann VITORADIAL 300-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitoradial 300-T
Type VR3
Oil condensing boiler with heat exchanger
VITORADIAL 300-T
5692 820 GB 9/2009 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 lists
Parts list, boiler..................................................................................................... 23
Parts list, heat exchanger..................................................................................... 26
Water quality
Water quality requirements.................................................................................. 29
Commissioning/service reports........................................................................ 32
Specification....................................................................................................... 33
Certificates
Declaration of conformity...................................................................................... 34
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 35
Keyword index.................................................................................................... 36
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. Matching the setting of the boiler control unit............ 7
•2. Checking the connections of the neutralising
equipment and filling with neutralising agent
••• 3. Commissioning the system........................................... 7
•4. Checking the burner adjustment................................... 8
• • 5. Shutting down the system
• • 6. Opening the boiler door................................................. 8
•7. Cleaning the internal pipes and heating surface......... 9
• • 8. Checking all seals/gaskets and packing cords on the
flue gas side
• • 9. Checking the thermal insulation parts of the boiler
door
•10. Inserting the internal pipes............................................ 10
• • 11. Fitting the boiler door..................................................... 11
• • 12. Checking all connections and the sensor well on the
heating water side for leaks
• • 13. Checking the function of the safety equipment........... 11
• • 14. Checking the diaphragm expansion vessel and
system pressure............................................................. 12
• • 15. Checking electrical plug-in connections and cable
entries for tightness
• • 16. Checking the heat exchanger gasket........................... 14
•17. Checking the water quality............................................ 18
• • 18. Checking neutralising equipment as per the
manufacturer's instructions and replacing used
neutralising agent
• • 19. Cleaning the sight glass in the boiler door.................. 20
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Checking the mixer for ease of operation and
tightness.......................................................................... 20
• • 21. Checking the function of the return temperature
raising facility (if installed)
• • 22. Checking the installation room ventilation
• • 23. Checking the flue for tightness
• • 24. Restarting the system
•25. Adjusting the burner...................................................... 21
•26. Instructing the system user........................................... 21
•27. Operating and service documents................................ 22
Commissioning, inspection, maintenance
Steps – commissioning, inspection and… (cont.)
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Matching the setting of the boiler control unit
Make the setting according to the infor-
mation in chapter "Additional informa-
tion, Coding" in the service instructions
for the control unit.
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
ventilation aperture is open.
03. Fill the heating system with water
and ventilate 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.
07. Open the flue gas damper (if instal-
led).
08. Check that the cleaning aperture on
the flue outlet is closed.
09. Open oil-line shut-off valves.
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 instruc-
tions).
11. When heating the system from cold
(also when restarting after mainte-
nance 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 con-
sumers 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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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.
Checking the burner adjustment
Burner service instructions
Opening the boiler door
4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the internal pipes and heating surface
1. Remove the internal pipes B; for
this, use the internal pipe extractor
A.
2. Clean flues C and combustion
chamber D with the brush.
Remove combustion residues with a
vacuum cleaner.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Inserting the internal pipes
AInsert internal pipes as far as they
will go
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Fitting the boiler door
4x
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 diaphragm expansion ves-
sel manufacturer's instructions.
Carry out this check on a cold system.
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 the
diaphragm expansion 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. 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 your heating system with
water and vent until the filling pres-
sure of a cooled system is 0.1 to 0.2
bar higher than the pre-charge pres-
sure of the diaphragm expansion
vessel.
Permiss. operating pressure: 4 bar
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-
controlled systems with integral
deaerating, 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 a longer service life of the
system components.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Boiler output kW up to 300
Diaphragm expansion vessel content litres 50
!Please note
The ingress of oxygen can result
in system damage as a conse-
quence of oxygen corrosion.
Furthermore ensure that only
pump-controlled pressure main-
taining 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
deaerating 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the heat exchanger gasket
Remove cover panel
4,8 x 9,5
ACover panel
Commissioning, inspection, maintenance
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Remove top panels
Commissioning, inspection, maintenance
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Remove back panel
3,9 x 9,5
ABack panel
Commissioning, inspection, maintenance
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Remove heat exchanger cover
1. Cut along the lower perforation A
(outer ring) of the cover's fabric lin-
ing.
2. Fold open the cut out fabric lining
D.
3. Remove heat exchanger cover C by
undoing the four hexagon screws.
4. Remove the gasket B and clean the
sealing face.
Assembly
in reverse order
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the water quality
See chapter "Water quality requirements".
Enter the volume of top-up water and the water hardness in the table.
Fill water Top-up water Meter reading Total water
volume
Date
m3m3m3m3
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—
—
—
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—
—
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—
—
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Max. fill volume: ...........................m3
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Total hardness pH value Water treatment Date
Feedwater Boiler water Boiler
water
Medium Metering
volume
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
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 820 GB