Viessmann VITOPLEX 300 Service Instructions Manual Download

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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.

Summary of Contents for VITOPLEX 300

Page 1: ...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 ...

Page 2: ...f 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 Norther...

Page 3: ...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 bee...

Page 4: ...g 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 Index 5692 818 GB ...

Page 5: ...r 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...

Page 6: ...eps 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 ...

Page 7: ...e 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 po...

Page 8: ...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 ma...

Page 9: ...9 4x Commissioning inspection maintenance Further details regarding the individual steps cont 5692 818 GB ...

Page 10: ...Clean flues C and combustion chamber D with the brush Remove combustion residues with a vacuum cleaner E 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 ...

Page 11: ...pipes A 3 B C A DE 1 2 A Insert internal pipes as far as they will go B Only for 500 kW C Hot gas flue D End stop E Spring clip Commissioning inspection maintenance Further details regarding the individual steps cont 5692 818 GB ...

Page 12: ...f explosion Test the tightness of all gas con nections 4x A A Tighten the screws diagonally Checking the function of the safety equipment Check the safety valves the water level and pressure limiters in accordance with manufacturer s details Commissioning inspection maintenance Further details regarding the individual steps cont 5692 818 GB ...

Page 13: ...t p0 pSt supplement The supplement is subject to the adjustment of the high limit safety cut out It is as follows for a high limit safety cut out set to 100 C 0 2 bar 110 C 0 7 bar 2 If the pre charge pressure of the dia phragm expansion vessel is lower than the static system pressure top up with nitrogen until the pre charge pressure is raised by 0 1 to 0 2 bar The static pressure corresponds to ...

Page 14: ...that only pump controlled pressure maintaining systems that are sealed against corrosion and protected against oxygen ingress into the heating water are used Pump controlled pressure main taining systems with atmospheric deaeration through cyclical pres sure release create a central post venting of the heating sys tem However this does not rep resent oxygen removal in the sense of corrosion protec...

Page 15: ...tal hardness pH value Water treat ment Date Feed water Boiler water Me dium Meter ing vol ume m3 m3 m3 dH dH The total hardness of the feed and top up water must not exceed 0 11 dH total value of alkaline earths 0 02 mol m3 The pH value should be between 9 and 10 5 Commissioning inspection maintenance Further details regarding the individual steps cont 5692 818 GB ...

Page 16: ... the mixer leaks 4 Snap the motorised lever into place Checking the Vitoair draught stabiliser if installed Release the latch on the control disc The control disc must swing freely during burner operation Adjusting the burner Burner service instructions or separate documentation from the burner manufacturer Adjust the maximum oil or gas through put of the burner to the rated boiler out put Commiss...

Page 17: ... the value of which is subject to the design of the flue system Operation with partial load Set the minimum output for the base load stage according to the conditions of the flue system Note that the flue system must be suitable for the low flue gas tem peratures that may occur It is recommended that the flue gas col lector is thermally insulated a motorised flue gas damper is installed and the mi...

Page 18: ...em user this part for safekeeping Retain the heating contractor s part 2 File all parts lists operating and serv ice instructions in the folder and hand this over to the system user The installation instructions are no longer required after the installation and therefore do not need to be retained Commissioning inspection maintenance Further details regarding the individual steps cont 5692 818 GB ...

Page 19: ...anel 208 Control unit fascia 209 Thermal insulation jacket 210 Thermal insulation mat back 211 Thermal insulation mat flue gas collector 212 Logo 213 Edge protection 214 Top fixing bracket 215 Bottom fixing bracket 216 Central side panel only from 390 kW 217 R h side panel back 218 L h side panel back Parts not shown 300 Installation instructions 301 Service instructions 302 Thermal insulation pac...

Page 20: ...20 B 012 008 009 212 200 208 207 206 019 020 001 002 010 214 214 003 007 006 005 004 022 021 Parts list Parts list cont 5692 818 GB ...

Page 21: ...203 213 213 211 217 205 014 014 013 210 202 016 015 017 201 215 215 C C D Quantity kW 90 115 140 180 235 300 390 Rated output Note on position number 013 11 500 9 8 5 6 6 5 5 018 209 Parts list Parts list cont 5692 818 GB ...

Page 22: ...rdness dH 50 to 200 2 0 11 2 200 to 600 1 5 8 4 The standard values assume the follow ing The volume of fill and top up water of the heating system during its service life will not exceed three times the water content of the heating system The specific system volume is less than 20 l kW output In multi boiler sys tems apply the output of the smallest boiler All measures to prevent corrosion on the...

Page 23: ...so observe the follow ing during commissioning Commission the system step by step starting with the lowest boiler output and a high heating water flow rate This prevents a localised concentra tion of limescale deposits on the boiler heating surfaces In multi boiler systems start all boilers simultaneously to prevent the entire limescale deposit settling in the heat transfer area of just one boiler...

Page 24: ...expansion vessel should be checked at least during the annual service For pressure main taining systems see chapter Checking the diaphragm expansion vessel and system pressure The use of permeable components e g plastic pipes that are permeable to gas in underfloor heating systems should be avoided Provide system separation if such components are nevertheless used This must separate the water flow...

Page 25: ...tically driven valves other types of valves gaskets etc If the system is filled with antifreeze it must be marked accordingly If a boiler system is changed to oper ate without antifreeze flush the sys tem in order to remove all traces of the antifreeze The quality of the boiler and feedwater must meet the requirements of VDI Directive 2035 The systems must be designed as sealed unvented systems as...

Page 26: ...r initial filling and commissioning but after 14 days at the latest clean the integral dirt trap so the heat trans fer medium can flow freely Following any losses through leaks or drawing off top up the antifreeze sol ution according to the concentration already in place Establish the volume of antifreeze as a check Water quality Using antifreeze in boilers cont 5692 818 GB ...

Page 27: ...rvice Service date by Service Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by Commissioning service reports Commissioning service reports 5692 818 GB ...

Page 28: ...d output 80 60 C 92 7 92 7 92 8 92 7 92 5 92 8 92 9 93 0 30 of rated output 60 50 C 97 3 97 4 97 5 97 5 97 1 97 6 97 7 97 9 Standby loss qB 70 0 40 0 37 0 32 0 34 0 37 0 29 0 25 0 23 Power consumption 3 at 100 of rated output W 359 430 482 544 612 695 789 30 of rated output W 123 143 161 181 204 232 263 2 Values for calculating the size of the flue system to EN 13384 relative to 13 CO2 for fuel oi...

Page 29: ...ith the following Directives this product is designated with _ 0085 2006 95 EC 92 42 EEC 2004 108 EC 98 37 EC 90 396 EEC This product meets the requirements of the Efficiency Directive 92 42 EEC for low temperature boilers boilers 400 kW The product characteristics determined as system values for the product Vitoplex 300 as part of EC type testing according to the Efficiency Directive see specific...

Page 30: ...x 9 in accordance with para 10 1 The standard seasonal efficiency to DIN of at least 94 according to para 6 2 Boiler and burner unit Vitoplex 300 with pressure jet oil burner Vitoplex 300 with pressure jet gas burner Boiler Vitoplex 300 Allendorf 20 April 2010 Viessmann Werke GmbH Co KG pp Manfred Sommer Certificates Manufacturer s certificate according to the 1st BImSchV Germany 5692 818 GB ...

Page 31: ...g the flue outlet 10 Cleaning the heating surface 10 Cleaning the sight glass in the boiler door 16 D Diaphragm expansion vessel 13 F Fill and top up water 15 I Instructing the system user 18 Internal pipes Cleaning 10 Inserting 11 O Operating and service documents 18 P Parts list 19 S System Commissioning 7 Filling with water 7 Venting 7 T Total hardness of the boiler water 15 V Vitoair draught s...

Page 32: ...0 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5692 818 GB Subject to technical modifications Printed on environmentally friendly chlorine free bleached paper ...

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