Viessmann Vitoflex 150-RF Service And Maintenance Instructions Download | Manualshive

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5797 342 - 01

Technical information subject to change without notice.

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Vitoflex 300-RF Service & Maintenance

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Summary of Contents for Vitoflex 150-RF

Page 1: ...ct 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 Servi...

Page 2: ...t 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 heati...

Page 3: ... 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 Ma...

Page 4: ...ents of the Biomass Boiler 14 Cleaning 15 Boiler 15 Heat exchanger displacement rods 16 Pneumatic cleaning system optional 17 Shutdown 17 Boiler 17 Extraction and conveyance systems 17 Control system 17 Ash disposal 17 Warning Message 18 Fault Message 18 Adjusting the Fuel Supply and Air Supply 24 Adjusting the Ash Removal 24 Visual Inspection of Combustion 25 Unjamming the Ash Removal Screw Conve...

Page 5: ...t 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 C22 2 N...

Page 6: ...er 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 othe...

Page 7: ...nd 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...

Page 8: ...g in moving parts and noise Power supply 120 1 60 VAC and 240 1 60 VAC 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 operati...

Page 9: ... 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 c...

Page 10: ... 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 develo...

Page 11: ...nd warm water after handling Suppliers of ceramic fiber products recommend the following first aid measures Respiratory tract nose and throat irritation If respiratory tract irritation develops move the person to a dust free location Eye irritation If eyes become irritated flush immediately with large amounts of lukewarm water for at least 15 minutes Eyelids should be held away from the eyeball to...

Page 12: ...anufacturing plants Photo processing plants Beauty salons Products containing contaminants Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Paint and varnish removers Hydrochloric acid muriatic acid Chlorine based swimming pool chemicals Spray cans containing chlorofluorocarbons Chlorinated waxes and cleaners Cements and glues Refrigerant leaks Calcium chlor...

Page 13: ...t properly observed and boiler damage results any warranty on the complete boiler and related components will be null and void General This equipment requires fresh air for safe operation The boiler location must never be under negative pressure Exhaust fans attic fans or dryer fans may cause air to be exhausted at a rate higher than air can enter the structure for safe combustion The heating cont...

Page 14: ...tomatic de ashing system optional 5 Igniter 6 Controlled combustion air supply system 7 Rotary blower Viessmann patented 8 Boiler door 9 Heat exchanger qP Rotary combustion chamber Viessmann patented qQ Safety heat exchanger for thermal safety flush valve qW Frequency controlled flue gas exhaust blower qE Pneumatic cleaning system optional qR Flue gas recirculation pipe Maintenance ...

Page 15: ...URY be absolutely sure to turn OFF the main switch CAUTION 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 After approx 1000 operating hours Clean the recirculated flue gas line After approx 300 operati...

Page 16: ...ed and the displacement rods can be easily removed Removing the displacement rods 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 Heat exchanger displacement rods The displacement rods improve the heat ...

Page 17: ...s and prevents expensive repairs Prevent the formation of condensation in the oxygen sensor Extend the service life of the buffer battery Ash disposal Ashes should be stored in covered metal containers on non combustible floors away from combustible material Comply with customary laws and local regulations on ash disposal Boiler Heat exchanger When the Vitoflex 300 RF is not in operation for a lon...

Page 18: ... the event of faults shut down the heating system and safeguard against reconnection Immediately notify faults to the responsible body or individual Rectify faults immediately When rectifying a fault no one else should be present in the danger zone around the heating system Prior to starting the heating system ensure that no one else is within the danger zone around the heating system Warning Mess...

Page 19: ...hermal contact infeed grate Electrical fault on drive motor Consult a qualified electrician Gearbox or bearing damage Replace gearbox or bearing 007 Fault Shut off gate valve sticks Spring return motor is faulty Repair or replace spring return motor Shut off gate valve does not reach end position Check for trapped foreign bodies and remove if necessary Check and adjust limit switch 008 Fault Rever...

Page 20: ...ion hydraulics container X Electrical fault on drive motor Consult a qualified electrician Bearing damage Replace bearing 017 Fault Temperature level hydraulics container X Loss of oil at the hydraulic unit Check the fittings lines and cylinders for leaks Top up the oil Pressure switch is incorrectly set or faulty Replace pressure switch Readjust setting for changeover pressure at pressure switch ...

Page 21: ...mperature sensor or test cable is faulty Consult a qualified electrician 036 Fault CAN connection inverter flue gas fan Inverter is faulty or there is no supply voltage at the inverter Consult a qualified electrician or Viessmann Technical Service 037 Fault Flue gas fan excess temperature Motor is overloaded due to excessive supply rate or as a result of bearing damage Consult a qualified electric...

Page 22: ...eration 002 Warning Maximum ash removal runtime exceeded Ash removal light barrier is dirty Clean transmitter and receiver of the light barrier Ash removal light barrier is faulty Consult Viessmann Technical Service 003 Warning System running without O2 control Lambda probe is severely contaminated or faulty O2 signal converter is faulty Consult Viessmann Technical Service 004 Warning Feed tube wa...

Page 23: ...emove material bridging in trough 012 Warning E filter bypass enabled Electrostatic filter for bypass has been active for over 30 minutes Check and remedy warning in accordance with message on electrostatic filter for bypass 013 Warning E filter cleaning enabled Electrostatic filter for cleaning has been active for over 30 minutes Check and remedy warning in accordance with message on electrostati...

Page 24: ...s not overloaded and the emission values are observed WARNING Risk of poisoning from carbon monoxide and carbonization gas as a result of incomplete combustion caused by overfilling with fuel Ensure that the fuel supply and air supply are adjusted correctly When changing to a different fuel adjust the parameters to suit the new fuel Adjusting the Ash Removal The amount of ash in the combustion cha...

Page 25: ...l screw conveyor 4 Stop the movement of the ash removal screw conveyor The ash removal screw conveyor comes to a halt 5 Open the inspection cover 6 7 Close the inspection cover 8 On the programming unit switch automatic mode back on The ash removal screw conveyor is now unjammed CAUTION Risk of crushing by and entanglement in the ash removal screw conveyor Never reach in through the maintenance co...

Page 26: ...ledges all currently unacknowledged fault messages Once acknowledged the fault message is then only displayed under History All fault messages All fault messages including those already acknowledged are shown on this screen The latest fault message is always at the top Once there are 100 fault messages the oldest message is deleted when a new one is generated Note Acknowledged messages are display...

Page 27: ...carry out maintenance work when the system has cooled down CAUTION Fuel emissions and incomplete combustion lead to the formation of life threatening carbon monoxide CO Carbon monoxide is a colourless odourless and tasteless extremely poisonous gas which in sufficient concentration results in death Always wear a mobile CO monitor when entering the fuel store rooms where fuel is transported and the...

Page 28: ...e safety equipment on the water side HC Check the respective alignment of the transmitters and receivers of light barriers E O Combustion chamber A Check infeed grate C for damage V Check the gasket of boiler door D for wear HC Check segment blocks A for damage O Check combustion chamber A for slag deposits and remove slag if necessary O Ash container optional Check ash container connection for ti...

Page 29: ...ration O Information on the compressor If the compressor is operating continuously this indicates that there is a leak in the compressed air system Check supply lines and valves for leaks In the case of on site supply of compressed air ensure that the compressor is suitable for continuous operation or can be prevented from operating continuously Cleaning the Boiler Information on cleaning the boil...

Page 30: ... D Open inspection cover G and check infeed grate F for contamination and slag deposits clean if necessary Cleaning interval depends on fuel and fuel quality O Check sight glass C and the sight glasses for light barriers H for contamination and clean if necessary When doing so remove any deposits from the apertures for the sight glasses O Remove ash below infeed grate F O Heat exchanger E Clean he...

Page 31: ... L and check maintenance cover for leaks O Pneumatic cleaning and compressor system Drain condensate from the compressor system O Information on flue gas path Check the lines and pipes of the flue gas path for tightness after cleaning and every six months Information on displacer rods Special tongs for removing the displacer rods are provided with the boiler Insert with the wide end of the displac...

Page 32: ...or together with impeller Clean with a brush or wire brush O Interior Open covers B and clean the guide blades of the flue gas dust extractor with a hand brush O Ash box Check gaskets C O Empty ash box D underneath the flue gas dust extractor Tip Check the fill level of the ash box daily Note Only operate the boiler with the ash box installed O Interval depends on the fuel and size of the ash box ...

Page 33: ... Horizontal discharge system Check and lubricate articulated arms articulated screws tension springs and tensioning chains Adjust articulated arms if required Funnel discharge Lubricate sealing washer between the discharge casing and geared motor and the universal joint of the screw conveyor Push rod discharge system Service the hydraulics in accordance with the operating instructions for the hydr...

Page 34: ...34 5797 342 01 Vitoflex 300 RF Service Maintenance ...

Page 35: ...35 5797 342 01 Vitoflex 300 RF Service Maintenance ...

Page 36: ...5797 342 01 Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Vitoflex 300 RF Service Maintenance ...

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