Viessmann VITOPLEX 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitoplex 300

Type TX3A

Oil/gas fired boiler

Rated output 620 to 2000 kW

VITOPLEX 300

5692 798 2/2009 Please keep safe.

Please follow these safety instructions 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

environmental pollution.

Note

Details identified by the word "Note"

contain 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

electrician.

■ The system must be commissioned by

the system installer or a qualified

person authorised by the installer.

Regulations

Observe the following when working on

this system

■ all legal instructions regarding the

prevention of accidents,

■ all legal instructions regarding

environmental 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)

Regulations

– the appropriate Building Regulation

either the Building regulations, the

Building Regulation (Scotland),

Building Regulations (Northern

Ireland),

– the Water Fittings Regulation or

Water Bylaws in Scotland,

– the current I.E.E. Wiring

Regulations.

If you smell gas

Danger

Escaping gas can lead to

explosions which may result in

serious injury.

■ Never 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.

■ Remove all people from the

danger zone.

■ Notify your gas or electricity

supplier from outside the

building.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 798

If you smell flue gas

Danger

Flue gas can lead to life-

threatening 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

supply 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

unauthorised reconnection.

!Please note

Electronic modules can be

damaged by electro-static

discharges.

Touch earthed objects, such as

heating or water pipes, to

discharge static loads.

Repair work

!Please note

Repairing components which

fulfil a safety function can

compromise 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

compromise its function.

Installing non-authorised

components and non-approved

modifications/conversion can

compromise safety and may

invalidate our warranty.

For replacements, use only

original spare parts from

Viessmann or those which are

approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5692 798

Commissioning, inspection, maintenance

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

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

Parts lists............................................................................................................ 17

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

Commissioning/service reports........................................................................ 25

Specification....................................................................................................... 26

Declaration of Conformity

Declaration of conformity...................................................................................... 27

Manufacturer's certificate

Manufacturer’s certificate according to the 1st BImSchV..................................... 28

Keyword index.................................................................................................... 29

Index

5692 798

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............................................. 8

•3. Opening the boiler door and clean-out cover.............. 9

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

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

• • 5. Checking all seals/gaskets and packing cords on the

flue gas side

• • 6. Checking the thermal insulation of the boiler door

•7. Inserting the internal pipes, fitting the boiler door and

clean-out cover............................................................... 11

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

heating water side

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

• • 10. Checking the diaphragm expansion vessel and

system pressure............................................................. 12

• • 11. Checking the tightness of electrical plug-in

connectors and cable grommets

• • 12. Checking the thermal insulation

• • 13. Checking the water quality............................................ 14

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

•15. Checking the mixer for ease of operation and leaks... 15

•16. Checking the function of the return temperature

raising facility (if installed)

• • 17. Checking the installation room ventilation

• • 18. Checking the flue pipe for tightness

•19. Adjusting the burner...................................................... 15

•20. Instructing the system user........................................... 16

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 798

Commissioning steps

Inspection steps

Maintenance steps Page

•21. Operating and service documents................................ 16

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5692 798

Commissioning the system

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 that internal pipes C are

pushed into hot gas flues B so that

safety spring D snaps into place

behind the first resistance E.

AInternal pipe extractor

03. Check that the installation room

ventilation aperture is open.

04. Fill the heating system with water

and ventilate the system.

Permissible operating pressure:

6 bar

!Please note

Unsuitable water qualities

can result in boiler body

damage.

According to VDI Directive

2035, the heating system

must be filled and operated

with water in which the sum

of alkaline earths must not

exceed 0.02 mol/m3.

Observe the "Water quality

requirements" on

page 22.

Note

Record the fill volume and water

hardness on page 14.

05. Check the system pressure.

06. Check the fuel oil level or the gas

supply pressure.

07. Open the flue gas damper (if

installed).

08. Check that the cleaning aperture on

the flue outlet is closed.

09. Open the gas or oil line shut-off

valves.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 798

10. Switch ON the main isolator, the

switch for the heating circuit pump

and the burner ON/OFF switch in

the order listed here (observe the

burner manufacturer's

instructions).

11. When heating the system from cold

(also when restarting after

maintenance and cleaning work),

prevent all heat transfer to

consumers, to clear the dew point

range as quickly as possible.

12. After the flow temperature has been

reached, switch ON the heat

consumers in sequence and

change the burner over to automatic

mode.

13. Check all gaskets/seals and plugs,

and retighten if necessary.

14. Check the boiler door and clean-out

cover after approx. 50 hours and

retighten all screws.

!Please note

During boiler heat-up, unpleasant

fumes and odours can result from

gases being expelled from the

thermal insulation, the heating

block and the paint.

Vent the room during

commissioning.

!Please note

When testing the flue gas for CO,

internal gases being expelled

from the heating block can cause

higher values.

Continue to operate the boiler

until a decline can be clearly

recognised.

Shutting down the system

1. Switch OFF the main isolator or the

power supply, and safeguard against

unauthorised reconnection.

2. Interrupt the burner power supply.

For this, pull the power supply plug-in

connectors fA and lÖ (if installed)

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.

!Please note

Draining the boiler with a suction

pump will create negative

pressure inside the boiler.

Drain the boiler with a suction

pump only when the air vent

valve has been cracked open.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 798

Opening the boiler door and clean-out cover

Note

In case of gas burners, remove the gas supply pipe.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 798

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

pipe

1. Remove internal pipes B with a

quick tug towards the front; for this,

use internal pipe extractor A, which

is part of the cleaning equipment.

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

clean-out aperture in flue outlet E

using a vacuum cleaner.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 798

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