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.
2
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
Safety instructions
5692 798
3
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
4
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
Index
5692 798
5
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
6
Commissioning steps
Inspection steps
Maintenance steps Page
•21. Operating and service documents................................ 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 798
7
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
8
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
9
Opening the boiler door and clean-out cover
Note
In case of gas burners, remove the gas supply pipe.
4x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 798
10
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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3
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