Viessmann VITORADIAL 300-T User manual

Installation instructions
for contractors
VIESMANN
Vitoradial 300-T
Type VR3
Condensing boiler with heat exchanger
VITORADIAL 300-T
5458 389 GB 1/2010 Dispose after installation.

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 appliances must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
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) Reg-
ulations
– 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.
Working on the system
■ 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 mains isolator.
■ Safeguard the system against unau-
thorised reconnection.
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
Safety instructions
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Installation sequence
Clearance dimensions.......................................................................................... 4
Boiler positioning and levelling............................................................................. 5
Connecting the heating water side....................................................................... 6
Making the safety connection and checking tightness......................................... 7
Fitting the thermal insulation to the boiler............................................................. 8
■ Boiler body thermal insulation........................................................................... 8
■Rear thermal insulation..................................................................................... 9
■Side panels and burner cables......................................................................... 10
■ Front panels...................................................................................................... 12
■ Preparing the control unit installation................................................................ 13
■ Rear panels....................................................................................................... 15
■ Type plate and logo.......................................................................................... 16
■ Control unit fascia............................................................................................. 17
Mounting the heat exchanger............................................................................... 18
■ Fabric lining, flue gas collector.......................................................................... 18
■ Frame, flue gas collector................................................................................... 19
■ Cover, flue gas collector................................................................................... 21
■ Top plates, boiler.............................................................................................. 22
■ Fabric lining, heat exchanger............................................................................ 24
■ Heat exchanger................................................................................................. 25
■ Fabric lining, heat exchanger (cont.)................................................................. 26
Hydraulic connection of the heat exchanger........................................................ 27
■ Hydraulic diagram............................................................................................. 27
■ Installing the flange........................................................................................... 28
■ Securing the mounting bracket......................................................................... 28
■ Cutting the pipes to length................................................................................ 29
■ Connecting pipes to flange............................................................................... 30
■ Fitting the circulation pump............................................................................... 31
■ Heat exchanger pipework................................................................................. 32
Fitting the heat exchanger thermal insulation....................................................... 37
■ Side panels....................................................................................................... 37
■ Front panel........................................................................................................ 38
■ Frame corner bracket........................................................................................ 39
■ Back panel........................................................................................................ 40
■ Cover panel....................................................................................................... 41
■ Top panels........................................................................................................ 42
■ Type plate......................................................................................................... 43
Fitting the flue gas high limit safety cut-out.......................................................... 44
Connection on the flue gas side........................................................................... 45
Burner installation................................................................................................. 45
Installing the combustion chamber sight glass..................................................... 45
Important information on commissioning.............................................................. 46
Index
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600
200 (100)
500 (50) a
b
500 (50)
100
20
28
M12
d
c
e
ABoiler
BBurner
CAdjustable anti-vibration feet (101 to
335 kW)
DAnti-vibration boiler supports (263
and 335 kW)
EHeat exchanger
Dimensions in brackets are minimum
clearances.
Rated output kW 101-157 201 263 335
a*1 mm 1100 1400 1600
bmm Observe the burner length
Adjustable anti-vibration feet
Permissible load kg 2000
Quantity pce 4
Anti-vibration boiler supports
Permissible load kg — — 2250
c (front) / number mm/pce — — 625/2
c (back) / number mm/pce — — 500/2
d mm — — 30
e (without load) mm — — 42
e (loaded) mm — — 37
*1 Maintain this space in front of the boiler to enable the withdrawal of the internal
pipes or to clean the hot gas flues.
Clearance dimensions
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2.
1.
1. Insert adjustable feet E into the
base rails.
Note
The adjustable feet and sight glass
closure may be found inside the com-
bustion chamber.
2. Level the boiler. Special foundations
are not required.
Note
We recommend installing the boiler on
adjustable anti-vibration feet C (see
chapter "Clearance dimensions") or
anti-vibration boiler supports D (see
chapter "Clearance dimensions").
Adjustable anti-vibration feet
Insert the adjustable feet from below into
the base rails.
Anti-vibration boiler supports
The ground must be level to within 1 mm,
to ensure even loading of the spring ele-
ments.
Position the boiler supports underneath
the boiler. For this, locate them centrally
underneath the base rails.
When setting the boiler down less than
square on, a boiler support can, tempo-
rarily, be overloaded. This can be pre-
vented by laying timbers (
□
35 mm)
under the front, centre and back of each
boiler support.
Boiler positioning and levelling
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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.
ABoiler return
up to 263 kW: DN 65
for 335 kW: DN 80
BFemale connection for Therm-Con-
trol temperature sensor, R½
CFemale connection for maximum
pressure limiter, R ½*2
DSafety connection (safety valve),
see page 7
FBoiler flow
up to 263 kW: DN 65
for 335 kW: DN 80
GFemale connection for boiler water
temperature sensor
HDrain, R 1¼
Note
For 300 kW without flash trap, a female
connection R ½, 110 mm long, is
required on site for the high limit safety
cut-out in the flow.
*2 For 335 kW, a low water indicator is required via a minimum pressure limiter;
installation via fitting assembly.
Connecting the heating water side
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Installation instructions, safety equipment block
Install the safety lines.
Safety connection for
101 to 201 kW R 1¼
263 and 335 kW R 1½
Permiss. operating
pressure
4 bar
Test pressure 5.2 bar
Low water indicator
According to EN 12828, a special low
water indicator can be omitted for boilers
up to 300 kW (except for attic heating
centres), as the standard boiler control
unit prevents heating when not permit-
ted.
Therm-Control start-up system
A shunt pump for raising the return tem-
perature is generally not required.
Ensure during the start-up phase (e.g.
during commissioning, after night and/or
weekend shutdowns), that the heating
circuit flow rate is reduced via the heat-
ing circuit control or via heating circuit
pumps (speed stages) to a max. of 50 %
(for multi-boiler systems max. 50 % of
the smallest boiler).
The heating circuit control or the heating
circuit pumps are regulated via the per-
manently (factory-)set Therm-Control
temperature sensor.
For further details regarding the Therm-
Control start-up control, see the relevant
technical guide.
For installation, see separate installation
instructions.
Note
Equip boilers with a safety valve which is
type-tested according to TRD 721 [or
local regulations] and which must be
marked in accordance with the relevant
system version.
Install all pipe connections free of load
and torque stresses.
!Please note
Unsuitable water quality can
damage the boiler body.
Only fill the boiler with water that
complies with the "Water quality
requirements" (see service
instructions and VDI Directive
2035).
Making the safety connection and checking tightness
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Note
All components required to fit the thermal insulation can be found in the thermal insu-
lation box.
Boiler body thermal insulation
4.
2. 1.
3.
ABlack side outwards
Note
Remove bag B containing the type
plate and Therm-Control temperature
sensor and keep safe. It will be needed
at a later stage.
Fitting the thermal insulation to the boiler
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Rear thermal insulation
2.
1.
Note
Check that the serial number on the type
plate matches the serial number stam-
ped into the back panel of the boiler.
Fitting the thermal insulation to the boiler (cont.)
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Side panels and burner cables
Note
Burner cables fA and lÖ are included in the thermal insulation pack.
4.
4x
4x M6
2.
1.
3.
Note
Secure the lower rails behind the boiler
base rails with screws.
Fitting the thermal insulation to the boiler (cont.)
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3.
4.
3.
2.
1.
8x
5.
41
90
ASide panels with holes on the
inside
Note
Route the burner cables on the side of
the boiler where the boiler door hinges
are located.
Fitting the thermal insulation to the boiler (cont.)
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Front panels
6.
3.9 x 9.5
5. 4.
3.9 x 9.5
2 mm
2.
1. 3.
Fitting the thermal insulation to the boiler (cont.)
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Preparing the control unit installation
Connections to the control unit back: see installation instructions, boiler control
unit.
Note
Boiler water temperature sensor § is supplied in the control unit pack.
Therm-Control temperature sensor aJ is in the bag on the boiler door.
The coding plug and the boiler logo are included with the product accessories.
Push the probe, the boiler water temperature sensor and the Therm-Control temper-
ature sensor as far as possible into the sensor wells.
Power supply plug fÖ is supplied with the control unit.
!Please note
Damaged capillary tubes result in incorrect sensor functions.
Never kink the capillary tubes.
1.
2.
6 x 12
Fitting the thermal insulation to the boiler (cont.)
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Note
Screws (6 x 12) can be found with the
control unit fascia (packed separately
with the thermal insulation).
1.
1.
2.
2.
ABoiler coding card
Fitting the thermal insulation to the boiler (cont.)
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Rear panels
5.
1. 2.
3,5 x 9,5
4.
3.
ABundle and secure the LV cables
Note
Pull all external cables through the aper-
tures in the back and front walls into the
control unit wiring chamber.
Installation instructions, boiler
control unit.
Fitting the thermal insulation to the boiler (cont.)
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Type plate and logo
1.
ABoiler type plate BLogo
Fitting the thermal insulation to the boiler (cont.)
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Control unit fascia
1.
Fitting the thermal insulation to the boiler (cont.)
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Fabric lining, flue gas collector
1.
2. 4x
AFabric lining, flue gas collector
Mounting the heat exchanger
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Frame, flue gas collector
1.
4.8 x 9.5
2 mm
6x
Mounting the heat exchanger (cont.)
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2.
6x
3.
AFrame, flue gas collector
Mounting the heat exchanger (cont.)
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