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
For applicability, see the last page
VITORADIAL 300-T
5692 820 GB 3/2013 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 inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered 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:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland), Build-
ing Regulations (Northern Ireland),
– 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.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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.
■ 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 installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
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.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5692 820 GB

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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 820 GB

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Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Parts lists
Parts list, boiler..................................................................................................... 27
Parts list, heat exchanger..................................................................................... 30
Water quality
Water quality requirements.................................................................................. 33
Commissioning/service reports........................................................................ 37
Specification....................................................................................................... 38
Certificates
Declaration of conformity...................................................................................... 39
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 40
Keyword index.................................................................................................... 41
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Product information
Intended use
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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 settings of the boiler control unit.......... 9
•2. Checking the connections of the neutralising system
and filling with neutralising agent
••• 3. Commissioning the system........................................... 9
•4. Checking the burner adjustment................................... 10
• • 5. Shutting down the system............................................. 11
• • 6. Opening the boiler door................................................. 11
•7. Cleaning the internal pipes and heating surface......... 12
••• 8. Checking all gaskets and packing cords on the flue
gas side
• • 9. Checking the thermal insulation components on the
boiler door
•10. Inserting the internal pipes............................................ 13
• • 11. Fitting the boiler door..................................................... 14
••• 12. Checking connections and sensor well for leaks on
the heating water side
••• 13. Checking the function of the safety equipment........... 15
••• 14. Checking the expansion vessel and system pressure 15
••• 15. Checking the firm seating of electrical plug-in
connections and cable grommets
••• 16. Checking the heat exchanger gasket........................... 17
• • 17. Cleaning the flue outlet and heat exchanger............... 21
• • 18. Checking the water quality............................................ 22
• • 19. Checking the neutralising system as per the
manufacturer's instructions and replacing used
neutralising agent
• • 20. Cleaning the sight glass in the boiler door.................. 24
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
••• 21. Checking the mixer for ease of operation and
tightness.......................................................................... 24
••• 22. Checking the function of the return temperature
raising facility (if installed)
••• 23. Checking the installation room ventilation
••• 24. Checking the flue pipe and all connections from the
heat exchanger to the flue system for tightness
• • 25. Restarting the system
• • 26. Adjusting the burner...................................................... 25
•27. Instructing the system user........................................... 26
•28. Operating and service instructions.............................. 26
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Matching the settings of the boiler control unit
Make the settings according to the infor-
mation in chapter "Additional informa-
tion, coding" in the control unit service
instructions.
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 (0.4 MPa)
!Please note
Scaling may result if the sys-
tem 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 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).
Commissioning, inspection, maintenance
Further details regarding the individual steps
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11. When heating the system from cold
(also when restarting after mainte-
nance and cleaning work), prevent
all heat supply to heat consumers,
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 out-
gassing from the thermal
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 clear decline
can be recognised.
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.
Only drain the boiler with a suc-
tion pump if the air vent valve is
open.
Checking the burner adjustment
Burner service instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Shutting down the system
Danger
Only open the connections on the
heating water side after the boiler
has been depressurised.
Only drain the boiler with a suc-
tion pump if the air vent valve is
open.
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
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.
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 21
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Inserting the internal pipes
A
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
A
AClose the door: Tighten screws
crosswise to 25 Nm.
Danger
Escaping gas leads to a risk of
explosion.
Check the boiler door for tight-
ness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 expansion vessel and system pressure
Note
Please observe expansion vessel man-
ufacturer's instructions.
Carry out this test on a cold system.
Expansion vessel
1. Drain the system until the pressure
gauge indicates "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 + supplement).
The supplement is subject to the set-
tings of the high limit safety cut-out.
For a high limit safety cut-out setting
of
■ 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 pres-
sure 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 pressure 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 require-
ments".
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 heating
output
kW up
to
300
up
to
500
up to
1000
DEV capacity litre 50 80 140
!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 enable central post-
ventilation of the heating system.
However, this does not represent
oxygen removal in the sense of
corrosion protection according 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 damaged.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the heat exchanger gasket
Removing the cover panel
4,8 x 9,5
ACover panel
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the top panels
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the back panel
3,9 x 9,5
ABack panel
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the heat exchanger cover
1. Cut open the fabric lining on the cover
at lower perforation A (outer ring).
2. Remove cut-out fabric lining D.
3. Remove heat exchanger cover C by
undoing the four hexagon screws.
4. Remove gasket B and clean the
sealing face.
Assembly
In reverse order
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 820 GB