Viessmann VITOTRANS 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitotrans 300
Flue gas/water heat exchanger
for Vitoplex
with rated output 575 to 2000 kW and
for Vitorond
with rated output 630 to 1080 kW
VITOTRANS 300
5692 790 GB 1/2009 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.
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....................................................... 6
Parts lists............................................................................................................ 16
Commissioning/service reports........................................................................ 21
Certificates
Declaration of Conformity..................................................................................... 22
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............ 6
•2. Checking the connections of the neutralising
equipment and filling with neutralising agent
•3. Checking system pressure and commissioning the
system
•4. Readjusting the burner (only when retrofitting the
heat exchanger).............................................................. 6
• • 5. Shutting down the boiler system.................................. 6
••• 6. Visually inspecting the gaskets on the inspection
cover and flue gas collector.......................................... 7
•7. Cleaning the heating surfaces....................................... 10
•8. Replacing damaged gaskets......................................... 14
••• 9. Assembly in reverse order
••• 10. Checking the water quality............................................ 14
••• 11. Checking neutralising equipment as per the
manufacturer's instructions and replacing used
neutralising agent
••• 12. Restarting the boiler
••• 13. Filling in the service report for commissioning/
maintenance.................................................................... 15
•14. Operating and service documents................................ 15
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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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.
Readjusting the burner (only when retrofitting the heat
exchanger)
Burner service instructions
Shutting down the boiler system
Switch OFF/isolate the main isolator
(outside the boiler room) and safeguard
against unauthorised reconnection.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Visually inspecting the gaskets on the inspection cover and flue
gas collector
ATop panel
BThermal insulation mat
CGauze mat
DInspection cover
EGasket
FCondensate drain
GLower flue pipe (flue gas outlet)
HConnection collar
Note on F
Not when commissioning
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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HConnection collar KUpper flue pipe (flue gas inlet)
LGauze jacket for flue gas collector
MThermal insulation jacket for flue
gas collector
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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NUpper flue gas collector OGasket
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the heating surfaces
ATop panel
BThermal insulation mat
CGauze mat
DInspection cover
EGasket
GLower flue pipe (flue gas outlet)
HConnection collar
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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With visible contamination:
HConnection collar KUpper flue pipe (flue gas inlet)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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LGauze jacket for flue gas collector MThermal insulation jacket for flue
gas collector
NUpper flue gas collector OGasket
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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PTurbulators
RHeating surfaces
SCondensate tray
Note on P
Check condition of turbulators.
Note on R
Clean heating surfaces thoroughly with
a water hose.
Note on S
If heavily contaminated, wipe conden-
sate tray and clean thoroughly with a
water hose.
!Please note
Prevent components that come
into contact with flue gas from
being scratched or otherwise
damaged.
Never use a wire brush or
sharp objects.
Prevent components that come
into contact with flue gas from
contact with pure iron, as corro-
sion damage can result. Use
plastic brushes if required.
For normal cleaning, rinse the heating
surfaces with a water jet.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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However, you may use cleaning agents
if you notice stubborn residues, surface
discolouration or soot deposits.
For this, observe the following:
■ Only use solvent-free cleaning agents.
Ensure that cleaning agent never gets
between the heat exchanger and the
thermal insulation.
■ Remove soot deposits with alkaline
agents containing surfactants (e.g.
Fauch 600*1).
■ Combustion residues may create thin,
yellow-brown surface discolouration
as well as hard deposits that may also
only become visible after removing the
soot deposits.
Use slightly acidic, chloride-free clean-
ing agents based on phosphoric acid
to remove surface discolouration and
hard deposits (e.g. Antox 75 E*1).
■ Remove loose deposits from the heat
exchanger; rinse the heating surfaces
and flue gas collector thoroughly with
a water jet.
Danger
Cleaning agents can irritate the
skin and eyes.
Wear goggles, protective gloves
and protective clothing if
required.
Cleaning agent manufacturer's
details.
Replacing damaged gaskets
Before fitting new gasket E to the
inspection cover (see page 10) and gas-
ket O to the flue gas collector (see
page 12), clean sealing faces.
Checking the water quality
Boiler service instructions
*1Manufacturer:
Hebro Chemie GmbH
Rostocker Straße 40
D -41199 Mönchengladbach
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Filling in the service report for commissioning/maintenance
You will find the service report on
page 21.
Operating and service documents
1. Complete and detach the customer
registration card:
■ Hand the section for system users
to the user for safekeeping.
■ Retain the section for contractors.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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When ordering spare parts:
Quote the part no. and serial no. (see
type plate), as well as the position num-
ber of the individual part (as per this parts
list).
Obtain standard parts from your local
supplier.
Parts
001 Upper flue gas collector*2
003 Upper cleaning cover
004 Upper cleaning cover packing 140
x 180
005 Packing 12 x 16 x 3000
007 Flange C 100*2
009 Gasket NW 100*2
011 Lower flue gas collector*2
013 Turbulator
014 Flue gas high limit safety cut-out
120 °C
200 Upper gauze mat
201 Gauze jacket for flue gas collector
202 Thermal insulation jacket
203 Thermal insulation jacket for flue
gas collector
204 Upper thermal insulation mat
205 Mounting bracket
206 Rail
207 Lower flue pipe side panel
208 Lower flue pipe cover panel
209 Side panel, return
210 Cover panel flanged aperture
211 Side panel
212 Central side panel
213 Side panel, flow
214 Upper flue pipe side panel
215 Upper flue pipe cover panel
216 Top panel
217 Central side panel
Parts not shown
002 Upper flue gas collector*3
006 Toggle fastener
008 Flange C 125*3
010 Gasket NW 125*3
012 Lower flue gas collector*3
300 Touch-up spray, Vitosilver
301 Touch-up paint stick, Vitosilver
302 Thermal insulation pack
303 Installation instructions
304 Service instructions
AType plate, optionally on the r.h. or
l.h. side
*2With AWT size 5
*3With AWT size 6
Parts lists
Parts lists
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216
215
214
212
213
212
211
208
211
209
212
A
210
217
207
Parts lists
Parts lists (cont.)
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205
206
206
205
206
206
205
Parts lists
Parts lists (cont.)
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202
203
201
200
204
Parts lists
Parts lists (cont.)
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005
001
004
003
013
009
007
009
007
011
Parts lists
Parts lists (cont.)
5692 790 GB