Viessmann Vitoflex 300-RF 150 Installations- und Benutzerhandbuch

Service and

Maintenance Instructions

for use by engineers and heating contractors

5603 880 - 03 12/2016

Read and save these instructions

for future reference.

Vitoflex 300-RF

Product may not be exactly as shown

If the information in this manual is not

followed exactly, a fire or explosion

may result causing property damage,

personal injury or loss of life.

Improper installation, adjustment and/or

operation could cause carbon monoxide

poisoning resulting in injury or loss of life.

This product must be installed and serviced

by a professional service technician who is

experienced and qualified in hot water boiler

installation and wood fuel combustion.

Do not store or use gasoline or other

flammable fluids in the vicinity of this or

any other appliance.

WHAT TO DO IF YOU SMELL FLUE GAS

Deactivate heating equipment

Open windows and doors.

Inform your heating contractor

Please file in Service Binder

WARNING

IMPORTANT

Vitoflex 300-RF 150, 220, 300, 400 and 540

Wood-fired Boiler

Output range: RF 150 154 - 512 MBH (45- 150 kW)

RF 220 205 - 751 MBH (60- 220 kW)

RF 300 273 - 1024 MBH (80- 300 kW)

RF 400 341 - 1365 MBH (100- 400 kW)

RF 540 478 - 1843 MBH (140- 540W kW)

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Safety, Installation and Warranty Requirements

WARNING

Installers must follow local regulations with respect

to installation of carbon monoxide detectors. Follow

manufacturer’s maintenance schedule of the boiler

contained in the section “Cleaning and Maintenance”.

Please ensure that these instructions are read and understood before commencing service and/or maintenance. Failure

to comply with the instructions listed below and details printed in this manual can cause product/property damage,

severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed

information found in manual subsections).

Product documentation

Read all applicable documentation before commencing

installation. Store documentation near boiler in a

readily accessible location for reference in the future

by service personnel.

For a listing of applicable literature,

please see section entitled “Important

Regulatory and Safety Requirements”.

Warranty

Information contained in this and

related product documentation must

be read and followed. Failure to do

so renders the warranty null and void.

Licensed professional heating contractor

The installation, adjustment, service and maintenance

of this equipment must be performed by a licensed

professional heating contractor.

Please see section entitled

“Important Regulatory and Installation

Requirements”.

Contaminated air

Air contaminated by chemicals can cause by-products

in the combustion process, which are poisonous to

inhabitants and destructive to Viessmann equipment.

For a listing of chemicals which

cannot be stored in or near the

boiler room, please see subsection

entitled “Mechanical Room”.

Advice to owner

Once the installation work is complete, the heating

contractor must familiarize the system operator/

ultimate owner with all equipment, as well as safety

precautions/requirements, shutdown procedure, and

the need for professional service.

Carbon monoxide

Improper installation, adjustment, service and/or

maintenance can cause flue products to flow into

living space. Flue products contain poisonous carbon

monoxide gas.

For information pertaining to the proper

installation, adjustment, service and

maintenance of this equipment to avoid

formation of carbon monoxide, refer to

the installation and operating instructions.

Fresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

For information pertaining to the

fresh air requirements of this product,

please see subsection entitled

“Combustion Air Supply”.

Equipment venting

Never operate the boiler without an installed venting

system. An improper venting system can cause

carbon monoxide poisoning.

For information pertaining to

venting and chimney requirements,

refer to the installation and operating

instructions. All products of

combustion must be safely vented

to the outdoors.

Introduction

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

About these Instructions

Introduction

Take note of all symbols and notations intended to draw attention to potential hazards or important

product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

CAUTION

Cautions draw your attention to the presence of potential

hazards or important product information.

WARNING



IMPORTANT

Indicates an imminently hazardous situation which,

if not avoided, could result in death, serious injury

or substantial product/property damage.

Indicates an imminently hazardous situation which,

if not avoided, may result in minor injury or product /

property damage.

Helpful hints for installation, operation or maintenance

which pertain to the product.

This symbol indicates to note additional information

This symbol indicates that other instructions must be

referenced.

Note: Viessmann Manufacturing Company Inc. reserves

the right to make product changes or updates

without notice and will not be held liable for

errors or omissions in the product literature.

Warnings draw your attention to the presence of potential

hazards or important product information.

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Table of Contents

Introduction

General Information

Safety

Maintenance

Troubleshooting

Safety, Installation and Warranty Requirements..............2

About these Instructions..............................................3

Product Information.....................................................5

Important Regulatory and Installation Requirements ........6

Safety Instructions......................................................8

Carbon Monoxide........................................................9

Extreme Weather Conditions......................................10

HazardousMaterial....................................................11

Mechanical Room.....................................................12

Combustion Air Supply..............................................13

Components of the Biomass Boiler..............................14

Cleaning..................................................................15

Boiler.................................................................15

Heat exchanger displacement rods........................16

Installing the displacement rods.............................16

Removing the displacement rods...........................16

Flue gas cyclone (optional)....................................17

Pneumatic cleaning system (optional)...................17

Feed systems...........................................................18

Shutdown...............................................................19

Boiler..................................................................19

Extraction and conveyance systems.......................19

Control system....................................................19

Replacing the buffer battery..................................19

Ash disposal........................................................19

Disposal of the boiler............................................19

Instructions regarding removal...............................19

Waste disposal....................................................19

Performance Problems...............................................20

Grate Drive Mechanics Jams.....................................21

Checking for increased Wear of Fireclay......................22

Checking the Inside of the Boiler Door.........................23

Checking

the Oxygen Control System.........................24

Balancing the Oxygen Sensor.....................................25

Heating System Faults..............................................26

Loader System Faults................................................27

Page

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Maximum allowable working pressure (water)…30 or 60 psi

Maximum water temperature…250°F (120°C) (closed loop)

Maximum boiler temperature……210°F (99°C) (open loop)

This boiler does not require a flow switch.

Viessmann solid-fuel boiler can only be installed and

serviced by qualified trained personnel.

Steel wood-fired hot water heating boiler.

For operation primarily with modulating boiler water

temperatures in closed loop forced circulation hot water

heating systems. Under certain conditions, open loop

systems may also be considered. Contact Viessmann

for details.

WARNING

Exposing the boiler to pressures and temperatures in

excess of those listed will result in damages and will

render the warranty null and void.

Product Information

General Information

Codes and standards

CSA B366.1-M91

Solid Fuel Fired Central Heating Appliances

CSA C.22.2#3-M88 (R2004)

Electrical Features of Fuel Burning Equipment

UL2523

Solid Fuel-Fired Hydronic Heating Appliances, Water Heat-

ers and Boilers

CSA B365-10

Installation Code for Solid Fuel Burning Appliances

and Equipment

ASME section IV boilers and pressure vessels

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Important Regulatory and Installation Requirements

Working on the equipment

The installation, adjustment, service, and maintenance

of this boiler must be done by a licensed professional

heating contractor who is qualified and experienced in the

installation, service, and maintenance of hot water boilers.

Ensure main power supply to equipment, the heating

system, and all external controls have been deactivated.

Take precautions to avoid accidental activation of power

during service work.

The completeness and functionality of field supplied

electrical controls and components must be verified

by the heating contractor. These include low-water

cut-offs, flow switches (if used), staging controls,

pumps, motorized valves, air vents, thermostats, etc.

Leave all literature at the installation site and advise

the system operator/ultimate owner where the

literature can be found. Contact Viessmann for

additional copies.

This product comes with several safety instruction

labels attached.

Do not remove!

Contact Viessmann immediately if replacement labels

are required.

Please carefully read this manual prior to attempting

service and maintenance. Any warranty is null and void

if these instructions are not followed.

For information regarding other Viessmann System

Technology componentry, please reference documentation

of the respective product.

We offer frequent installation and service seminars to

familiarize our partners with our products. Please inquire.

RISK OF INJURY: Shut the system off before starting

any cleaning. Be absolutely sure to wear protective

gloves, protective eyewear if required and use the

cleaning tools that come with the system (danger of

blow-ups, burns and getting crushed)!

CAUTION

Technical literature

Literature applicable to all aspects of the Vitoflex 300-RF

wood-fired boiler:

- Installation and Operating Instructions

- Service and Maintenance Instructions

- Field Wiring Diagram

General Information

5603 880 - 03

Vitoflex 300-RF Service & Maintenance General Information

WARNING

The boiler must not be located in areas or rooms where

chemicals are stored or aggressive vapors from (i.e.

bleach, hair spray, methyl chloride, carbon tetrachloride

or perchloroethylene) or high dust levels or humidity

levels are present. Heat exchanger corrosion might

occur and reduce the lifetime of the boiler significantly.

If above criteria are not properly observed and boiler

damage results, any warranty on the complete boiler

and related components will be null and void.

Important Regulatory and Installation Requirements (continued)

Regular maintenance and service

The entire heating system must be cleaned and serviced

on a regular basis by a qualified contractor or service

agency to ensure reliable, energy-efficient, and

environmentally friendly operation.

The build-up of soot on the heat exchanger raises the

flue gas temperature and reduces efficiency.

IMPORTANT

Keep boiler and boiler room clear and free of combustible

materials, gasoline and other flammable vapors and

liquids. Do not obstruct the flow of combustion and

ventilation air. All inspection, maintenance and service

must be performed by a qualified heating contractor.

WARNING

Improper installation, adjustment, service or maintenance

can cause flue products to flow into living space. Flue

products contain poisonous carbon monoxide gas, which

can cause nausea or asphyxiation resulting in severe

personal injury or loss of life.

WARNING

Service and maintenance can only be performed by a

qualified heating contractor.

Important to know

Do not use this boiler if any part has been under, or

exposed to, water. Immediately call a qualified heating

contractor to inspect the boiler and to replace any

part of the control system, which has been under or

exposed to water.

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

If you notice fire coming from the appliance, call the fire

department immediately!

DO NOT attempt to extinguish the fire unless qualified to

do so.

WARNING

Fire causes a risk of burns and explosion!

Shut down the boiler

Close fuel shut-off valves

Use a tested fire extinguisher, class ABC.

Safety Instructions

IMPORTANT

The local building codes and regulations must be followed

by the heating contractor.

IMPORTANT

Please refer to the Installation and Operating

Instructions for installation, commissioning

and technical specification information. The

“Installation and Operating Instructions” contain

the necessary safety and national/local code

requirements which, if not followed exactly,

may lead to property damage, personal injuries

and/or death.

Important Information

Safety instructions

When carrying out work on the heating system, such as

cleaning and maintenance, wear appropriate protective

equipment when required.

There is a danger of getting injured through: burning,

knocking against corners and edges, crushing in moving

parts and noise.

Power supply: 120V or 240V/1/ and 208V/3/ 60Hz

In case of an emergency, the Vitoflex 300-RF can be

disconnected from the electrical power supply at all the

leads by the main switch on the control cabinet.

CAUTION

FIRE HAZARD:

The boiler must NEVER be operated with the doors open!

Any burning bits that escape could start a fire.

RISK OF INJURY:

If the doors are open during operation, sparks or flames

could leap out.

Equipment for dissipating excess heat: a competent

specialist should examine the operational reliability of

the thermal safety flush valve annually. The safety

heat exchanger must not by any means be used as an

operational heat exchanger.

Seals: for the functioning and controllability of the boiler,

it is important that no unwanted air can enter unchecked

through leaks.

The doors and lids have to shut tight - any damaged

seals must be replaced immediately. Tighten the retaining

screws and handles well.

Operation, cleaning and maintenance: bear in mind that

even the best product can only fulfill its functions well,

doing so for a long time and free of malfunctions, if

operated and maintained properly.

Compliance with the “Cleaning” section is mandatory!

IMPORTANT

Doors: for safety keep firing and ash pit doors tightly closed

Safety

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Carbon Monoxide

Carbon monoxide

The U.S. Consumer Product Safety Commission strongly

recommends the installation of carbon monoxide detectors

in buildings in which wood-burning equipment is installed.

Carbon monoxide (CO) is a colorless, odorless gas, which

may be produced during incomplete combustion of fuel

and/or when the flame does not receive an adequate

supply of combustion air. Carbon monoxide can cause

severe personal injury or loss of life.

Therefore, carbon monoxide detectors that are in

compliance with a nationally recognized standard

(e.g. ANSI/UL 2034-2002, CSA 6.19-01) should be

installed and maintained in buildings that contain

wood-burning equipment.

Note: Viessmann does not test any detectors and makes

no representation regarding any brand or type of

detector.

For safe operation

We recommend that you frequently:

- Check for debris which could obstruct the flow of

flue gases. The vent or chimney must not be blocked.

A blocked or partially blocked vent or

chimney can cause flue gases to leak into the

structure. Flue gases leaking into the house can

cause injury or death. Blocked or partially blocked

chimneys must have the blockage removed by a

qualified heating contractor.

- Check pressure gage for correct system (water)

pressure. Check for water on the floor from the

discharge pipe of the pressure relief valve or any

other pipe, pipe joint, valve or air vent.

- Check for moisture, water, or appearance of rust

on the flue gas pipes, their joints as well as vent

dampers, or side wall vent terminals (if so equipped).

- Ensure that nothing is obstructing the flow of

combustion and ventilation air and no chemicals,

garbage, gasoline, combustible materials, flammable

vapors and liquids are stored (not even temporarily)

in the vicinity of the boiler.

- DO NOT allow unsupervised children near the boiler.

Service/inspection of the boiler and the system must be

performed on a regular basis. Maintenance, service and

cleaning are specified in the section “Maintenance”.

Before the heating season begins, it is recommended that

the boiler be serviced by a qualified heating contractor.

WARNING

Improper installation, adjustment, service or maintenance

can cause flue products to flow into living space. Flue

products contain poisonous carbon monoxide gas, which

can cause nausea or asphyxiation resulting in severe

personal injury or loss of life.

WARNING

The operator/ultimate owner is required to have the heating

boiler and controls checked, as a minimum once per year,

by the original installer or by a competent heating

contractor familiar with the equipment. Defects must

be corrected immediately.

Safety

5603 880 - 03

Vitoflex 300-RF Service & Maintenance

Safety

Extreme Weather Conditions

WARNING

As there are no user-serviceable parts on the boiler,

or control, the end-user must not perform service

activities of any kind on system components. Failure

to heed this warning can cause property damage,

severe personal injury or loss of life.

Frozen water pipe hazard

Your heating boiler is designed to provide a warm and

comfortable living environment. It is NOT designed to

ensure against freezing of water pipes. The boiler is

equipped with several safety devices that are designed

to shut down the boiler and to prevent it from

restarting in the event of various unsafe conditions.

If your boiler remains off for an extended period of time

during cold weather, water pipes may freeze and burst,

resulting in extensive water damage and conditions in

which mold could grow. Certain molds are known to

cause respiratory problems, as well as to pose other

serious health risks. In case of water damage, immediate

measures should be taken to dry out affected areas as

quickly as possible to prevent mold from developing.

If the building will be unattended for an extended period

of time during cold weather, you should...

Shut off the water supply to the building, drain the water

pipes and add antifreeze for potable water to drain traps

and toilet tanks. Open faucets where appropriate.

or…

Have someone check the building frequently during cold

weather and call a qualified service agency if required.

or...

Install a reliable remote temperature sensor that will notify

somebody of freezing conditions within the building.

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