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Viessmann Vitoflex 300-RF Series, Service And Maintenance Instructions, Page: 4 / 28

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Viessmann Vitoflex 300-RF Series Service And Maintenance Instructions Download Page 4

4

5603 880  - 03

Vitoflex 300-RF Service & Maintenance

Table of Contents

Introduction

General Information

Safety

Maintenance

Troubleshooting

Safety, Installation and Warranty Requirements

..............2

About these Instructions

..............................................3

Product Information

.....................................................5

Important Regulatory and Installation Requirements

 ........6

Safety

 

Instructions

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

Carbon Monoxide........

................................................9

Extreme Weather Conditions

......................................10

Hazardous Material......

..............................................11

Mechanical Room

.....................................................12

Combustion Air Supply

..............................................13

Components of the Biomass Boiler

..............................14

Cleaning

..................................................................15 

      Boiler.................................................................15

 

Heat exchanger displacement rods........................16

 

Installing the displacement rods.............................16

 Removing 

the 

displacement rods...........................16 

 

Flue gas cyclone (optional)....................................17

 Pneumatic 

cleaning 

system 

(optional)...................17

Feed systems

...........................................................18

Shutdown

...............................................................19

 Boiler..................................................................19

 

Extraction and conveyance systems.......................19

 Control 

system....................................................19

 Replacing 

the buffer battery..................................19

 Ash 

disposal........................................................19

 

Disposal of the boiler............................................19

 

Instructions regarding removal...............................19

 Waste 

disposal....................................................19

Performance Problems

...............................................20

Grate Drive Mechanics Jams

.....................................21

Checking for increased Wear of Fireclay

......................22

Checking the Inside of the Boiler Door

.........................23

Checking the Oxygen Control System

.........................24

Balancing the Oxygen

 

Sensor

.....................................25

Heating System Faults

..............................................26

Loader System Faults

................................................27

 

Page

Summary of Contents for Vitoflex 300-RF Series

Page 1: ...life This product 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 Pleas...

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: ...15 Boiler 15 Heat exchanger displacement rods 16 Installing the displacement rods 16 Removing the displacement rods 16 Flue gas cyclone optional 17 Pneumatic cleaning system optional 17 Feed systems 18 Shutdown 19 Boiler 19 Extraction and conveyance systems 19 Control system 19 Replacing the buffer battery 19 Ash disposal 19 Disposal of the boiler 19 Instructions regarding removal 19 Waste disposa...

Page 5: ...irculation hot 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 Appliance...

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: ... in moving parts and noise Power supply 120V or 240V 1 and 208V 3 60Hz 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: ...erly 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 contractor...

Page 14: ...tic 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: ... broom or wire brush After every cleaning of the boiler heat exchanger Open the side lids and clean the guide blades of the cyclone with a hand brush Check the level of the ash container regularly and empty the bin before it is completly full Never operate the boiler without an ash bin IMPORTANT Pneumatic cleaning system optional Operation and maintenance of the air compressor optional according t...

Page 18: ...AP APS Lubricate the gasket between the extraction casing and the geared motor and universal joint for the auger If a fuel hopper is installed do not alter equipment in any way May be connected to an existing boiler or solar system 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 t...

Page 19: ...en sensor Extend the service life of the buffer battery Replacing the buffer battery The buffer battery is built in beneath the removable lid on the control module type Panasonic Lithium BR2330 It is for buffering the time date and settings Note The battery needs replacing every five years DO NOT disconnect the main power or turn off the main switch while changing the battery Ash disposal Ashes sh...

Page 20: ...rformance Boiler re establishes its performance Boiler reestablishes its performance Boiler re establishes its performance Residual oxygen ACTUAL Residual oxygen TARGET Fuel W35 Open primary air vent Check that grate vents move smoothly Contact Viessmann 1 Clean grate 2 Clean all four sight glasses and pipes of the ember monitoring system light barrier 3 Check the position of the light barrier F3 ...

Page 21: ...ecting rod and of the bronze bearing by means of grease removers Check grate for foreign material Are all grate components properly inserted Lateral play sliding grate for the concrete 3 16 1 32 5 1 mm applies up to RF 300 5 16 1 16 8 2 mm applies up to RF 400 540 Crank axle distance RF 100 150 1e 35 mm RF 220 300 25 32 55 mm RF 400 540 35 32 80 mm Setting stop position sliding grate back crank dr...

Page 22: ...d on the back of the fireclay can be seen in the substructure Checking for increased wear of fireclay Check the recirculation system Check damper Check fireclay for discoloration Cleaning in the area of the arch in the chimney and in the area of the opening of the shut off valve Recirculation must be hot at partial load Damper must be installed Damper must not be fully open chimney draft may be to...

Page 23: ...door Check guide tube for deformation possible cause of deformation Overheating If there is increased wear of the fireclay perform check see section checking for increased wear of Fireclay Check guide tube for wear Seal must fit properly and be caulked Procedure if a seal is leaking Replace ceramic packing of the seal check by means of impression test that the whole surface of the seal lies on the...

Page 24: ...eck the boiler Clean the outside of the oxygen sensor using a wire brush Hold the oxygen sensor downwards and gently tap out with the bristles of the wire brush until no more dirt falls out of the probe Check that all electrical lines are permanently connected Balance the oxygen sensor see section on balancing the oxygen sensor Set the heating system to cleaning Check the leak tightness of the ins...

Page 25: ...ly in the air without contact to metal Measure the oxygen sensor signal Boiler status off Balance the oxygen sensor Install the oxygen sensor The oxygen sensor must be supplied with a heating voltage in the range between 13 0 and 13 8V measured at the white white wires The heating voltage can be adjusted on the main board The signal voltage must be in the range between 6 and 11 mV measured at the ...

Page 26: ...ombustion chamber filling time is too short Use suitable dry fuel Readjust oxygen sensor Replace ignition device Readjust combustion chamber Acknowledge with OK 20 Water level in extinguishing Water container red light at F3 Level float switch in extinguishing water container Not enough water in the extinguishing water container Fill extinguishing water container Acknowledge with OK 25 Light barri...

Page 27: ... 31 45 Conveyor device red light at F4 Maintenance cover limit switch One of the maintenance covers is open or not closed properly Check and close all the maintenance covers Acknowledge with OK 51 52 Extraction system red light at F4 Maintenance cover limit switch One of the maintenance covers is open or not closed properly Check and close all the maintenance covers Acknowledge with OK 53 54 Extra...

Page 28: ...5603 880 03 Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Vitoflex 300 RF Service Maintenance ...

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