Viessmann VITOPLEX 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitoplex 300

Type TX3A, 90 to 500 kW

Oil/gas boilers

For applicability, see the last page

VITOPLEX 300

5692 818 GB 5/2011 Please keep safe.

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 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

5692 818 GB

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.)

5692 818 GB

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance.......................................... 5

Further details regarding the individual steps....................................................... 7

Parts list.............................................................................................................. 19

Water quality

Water quality requirements.................................................................................. 22

Using antifreeze in boilers.................................................................................... 25

Commissioning/service reports........................................................................ 27

Specification....................................................................................................... 28

Certificates

Declaration of conformity...................................................................................... 29

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 30

Keyword index.................................................................................................... 31

Index

5692 818 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Commissioning the system........................................... 7

• • 2. Shutting down the system

• • 3. Closing the Vitoair draught stabiliser (if installed)...... 8

• • 4. Opening the boiler door and cleaning cover............... 8

•5. Cleaning the internal pipes, heating surface, flue

outlet and flue................................................................. 10

••• 6. Checking all gaskets and packing cords on the flue

gas side

• • 7. Checking the thermal insulation parts of the boiler

door

•8. Inserting the internal pipes............................................ 11

• • 9. Securing the boiler door and cleaning cover............... 12

••• 10. Checking connections and sensor well for leaks on

the heating water side

••• 11. Checking the function of the safety equipment........... 12

••• 12. Checking the diaphragm expansion vessel and

system pressure............................................................. 13

••• 13. Checking the firm seating of electrical plug-in

connections and cable grommets

••• 14. Checking the thermal insulation

• • 15. Checking the water quality............................................ 14

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

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

tightness.......................................................................... 16

••• 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

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance

5692 818 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 21. Checking the Vitoair draught stabiliser (if installed)... 16

• • 22. Adjusting the burner...................................................... 16

•23. Instructing the system user........................................... 18

•24. Operating and service documents................................ 18

Commissioning, inspection, maintenance

Steps – commissioning, inspection and… (cont.)

5692 818 GB

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

04. Record the fill volume and water

hardness (see chapter "Checking

the water quality").

!Please note

Scaling may result if the sys-

tem is not operated with fully

softened heating water.

Observe the instructions in

chapter "Water quality

requirements".

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).

11. When heating the system from cold

(also when restarting after mainte-

nance and cleaning work), prevent

any heat supply to the heat consum-

ers 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 gases

being expelled from the ther-

mal 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 decline can be

clearly recognised.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 818 GB

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.

Drain the boiler with a suction

pump only when the air vent

valve has been opened.

Closing the Vitoair draught stabiliser (if installed)

1. Start the burner. 2. With the pre-purge running, shut

down the system. The control disk will

then be closed.

Opening the boiler door and cleaning cover

Note

On systems with gas burners, remove

the gas supply pipe.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 818 GB

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 818 GB

Cleaning the internal pipes, heating surface, flue outlet and flue

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 and the flue outlet through the

cleaning aperture in flue outlet E

using a vacuum cleaner.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 818 GB

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