Viessmann VITOPLEX 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitoplex 300

Type TX3A, 620 to 2000 kW

Oil/gas boiler

VITOPLEX 300

5692798 GB 9/2020 Please keep safe.

Please follow these safety instruc-

tions closely to prevent accidents

and material 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 environmen-

tal pollution.

Note

Details identified by the word "Note"

contain additional information.

Target group

These instructions are exclusively inten-

ded for qualified contractors.

■Work on gas installations may only be

carried out by a registered gas fitter.

■Work on electrical equipment may only

be carried out by a qualified electrician.

■The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations to be observed

■National installation regulations

■Statutory regulations for the prevention

of accidents

■Statutory regulations for environmental

protection

■Codes of practice of the relevant trade

associations

■Relevant country-specific safety regu-

lations

Safety instructions for working on the system

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.

■Wear suitable personal protective

equipment when carrying out any work.

Safety instructions

5692798

Danger

Hot surfaces and fluids can lead to

burns or scalding.

■Before maintenance and service

work, switch OFF the appliance

and let it cool down.

■Never touch hot surfaces on the

boiler, burner, flue system or pipe-

work.

!Please note

Electronic assemblies can be dam-

aged by electrostatic discharge.

Prior to commencing work, touch

earthed objects such as heating or

water pipes to discharge static

loads.

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise the

safe operation of the system.

Replace faulty components only

with genuine Viessmann spare

parts.

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that have

not been tested together with the

system can compromise its func-

tion. Installing non-authorised com-

ponents and making non-approved

modifications or conversions can

compromise safety and may invalid-

ate our warranty.

For replacements, use only original

spare parts supplied or approved by

Viessmann.

Safety instructions

Safety instructions (cont.)

5692798

Safety instructions for operating the system

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. Never switch

lights or electrical appliances 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 sup-

ply utility from outside the building.

■Have the power supply to the

building shut off from a safe place

(outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening

poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to

prevent flue gases from spread-

ing.

What to do if water escapes from the

appliance

Danger

If water escapes from the appliance

there is a risk of electrocution.

Switch OFF the heating system at

the external isolator (e.g. fuse box,

domestic distribution board).

Danger

If water escapes from the appliance

there is a risk of scalding.

Never touch hot heating water.

Condensate

Danger

Contact with condensate can be

harmful to health.

Never let condensate touch your

skin or eyes and do not swallow it.

Flue systems and combustion air

Ensure that flue systems are clear and

cannot be sealed, for instance due to

accumulation of condensate or other

external causes.

Ensure an adequate supply of combus-

tion air.

Inform system users that subsequent

modifications to the building characteris-

tics are not permissible (e.g. cable/pipe-

work routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or

an inadequate supply of combus-

tion air can cause life threatening

poisoning from carbon monoxide in

the flue gas.

Ensure the flue system is in good

working order. Vents for supplying

combustion air must be non-seala-

ble.

Extractors

Operating appliances that exhaust air to

the outside (extractor hoods, extractors,

air conditioning units, etc.) can create

negative pressure. If the boiler is oper-

ated at the same time, this can lead to a

reverse flow of flue gas.

Safety instructions

Safety instructions (cont.)

5692798

Danger

The simultaneous operation of the

boiler and appliances that exhausts

air to the outside can result in life

threatening poisoning due to a

reverse flow of flue gas.

Fit an interlock circuit or take suita-

ble steps to ensure an adequate

supply of combustion air.

Safety instructions

Safety instructions (cont.)

5692798

1. Information Symbols ................................................................................................. 7

Intended use .......................................................................................... 7

Product information ................................................................................ 8

System examples .................................................................................. 8

Spare parts lists ..................................................................................... 8

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 9

3. Water quality Water quality requirements .................................................................... 18

■Heating systems with rated operating temperatures up to 100 °C

(VDI 2035) .......................................................................................... 18

■Prevention of damage through corrosion on the water side ............... 19

Using antifreeze in boilers ..................................................................... 19

4. Commissioning/service

reports

Water quality .......................................................................................... 21

Maintenance/service .............................................................................. 21

5. Specification ................................................................................................................ 23

6. Decommissioning and dis-

posal

Final decommissioning and disposal ..................................................... 24

7. Certificates EU Declaration of Conformity ................................................................ 25

Manufacturer's certificate according to BImSchV .................................. 25

8. Keyword index ................................................................................................................ 26

Index

5692798

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not dispose of component in

domestic waste.

The steps in connection with commissioning, inspec-

tion and maintenance are found in the "Commission-

ing, inspection and maintenance" section and identified

as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions 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 purpose other

than the heating up of heating water shall be deemed

inappropriate.

Intended use presupposes that a fixed installation in

conjunction with permissible components designed for

this purpose has been carried out.

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufac-

turer's liability.

Any usage beyond this must be approved by the man-

ufacturer for the individual case.

Intended use also includes the adherence to mainte-

nance and inspection intervals.

Information

Symbols

5692798

Vitoplex 300, type TX3A

■Fuels: Fuel oil and natural gas

■Permissible operating pressure 6 bar (0.6 MPa)

■Rated heating output 620 to 2000 kW

System examples

Available system examples: See

www.viessmann-schemes.com.

Spare parts lists

Information about spare parts can be found at

www.viessmann.com/etapp or in the Viessmann

spare part app.

Information

Product information

5692798

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Commissioning the system............................................................................................... 10

• • 2. Shutting down the system................................................................................................. 10

• • 3. Opening the boiler door and cleaning cover................................................................... 11

•4. Cleaning the internal pipes, heating surface, flue outlet and flue pipe........................ 11

• • 5. Checking all gaskets and packing cords on the flue gas side

• • 6. Checking the thermal insulation components on the boiler door................................. 12

•7. Inserting internal pipes; securing the boiler door and cleaning cover......................... 13

• • 8. Checking connections and sensor well on the heating water side for tightness

• • 9. Checking the function of safety equipment..................................................................... 13

••• 10. Checking the function of the pressure switch................................................................ 14

• • 11. Checking the expansion vessel and system pressure................................................... 14

•12. Checking the temperature controller setting if a building management system is

used (DCC system)............................................................................................................ 15

• • 13. Checking the firm seating of electrical plug-in connections and cable grommets

• • 14. Checking the thermal insulation

• • 15. Checking the water quality................................................................................................ 15

• • 16. Cleaning the sight glass in the boiler door...................................................................... 15

•17. Checking the mixer for ease of operation and tightness............................................... 15

•18. Checking the function of the return temperature raising facility (if installed)

• • 19. Checking the installation room ventilation

• • 20. Checking the flue pipe for tightness

•21. Adjusting the burner.......................................................................................................... 16

•22. Instructing the system user.............................................................................................. 17

•23. Operating and service documents................................................................................... 17

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692798

Operating and service instructions for the control

unit and the burner

01. Close the gas shut-off valve and open the boiler

door.

02. Check internal pipes C are correctly inserted into

hot gas flues B. Spring clip D of the internal

pipes must lock into place behind first constriction

Fig. 1

AInternal pipe extractor

03. Check that the ventilation air aperture in the instal-

lation room is open.

04. Fill the heating system with water and vent the

system.

Permissible operating pressure: 6 bar (0.6 MPa)

05. Record the amount of fill water and its hardness in

chapter "Checking the water quality".

!Please note

Unsuitable water quality can damage the

boiler body.

Operate boilers only with softened water.

Observe the instructions in chapter "Water

quality requirements" on page 18.

06. Check the system pressure.

07. Check the oil level or the gas supply pressure.

08. Open the flue gas damper (if installed).

09. Check that the cleaning aperture on the flue outlet

is closed.

10. Open the shut-off valves in the oil or gas line.

11. Switch ON the mains isolator, the switch for the

heating circuit pump and the burner ON/OFF

switch, in that order. Observe the burner manufac-

turer’s operating instructions.

12. The dew point range must be cleared as quickly

as possible. For this reason prevent all heat sup-

ply to consumers when heating the system from

cold. This also applies when restarting after main-

tenance and cleaning work.

!Please note

During boiler heat-up, unpleasant fumes

and odours can result from outgassing from

the thermal insulation, the thermal block

and the paint.

Ventilate the room during commissioning.

13. Once the flow temperature has been reached,

successively switch on the heat consumers.

Switch the burner over to automatic mode.

!Please note

Internal gas emissions from the thermal

block can lead to increased CO values in

the flue gas.

Continue to operate the boiler until a decline

can be clearly recognised.

14. Check all gaskets and plugs, and retighten if nec-

essary.

15. Check the boiler door and cleaning cover after

approx. 50 hours run and retighten all screws.

Shutting down the system

1. Switch OFF the mains isolator or the power supply,

and safeguard against unauthorised reconnection.

2. Interrupt the burner power supply. If installed, pull

plug-in connectors fA and lÖ from the burner.

3. Close the gas shut-off valve.

Danger

Heating water escaping under pressure will

injure bystanders.

Only open the connections on the heating water

side after the boiler has been depressurised.

Commissioning, inspection, maintenance

Commissioning the system

5692798

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