Viessmann VITOTRANS 300 Service Instructions Manual

Brand: Viessmann

Model: VITOTRANS 300

Type: Service Instructions Manual

Viessmann VITOTRANS 300 provides an efficient and reliable way of exchanging heat between flue gas and water. The system can be commissioned, inspected, and maintained by trained personnel, to ensure optimal performance for the user.

Service instructions

for contractors

VIESMANN

Vitotrans 300

Flue gas/water heat exchanger

for Vitoplex

with rated output 575 to 2000 kW and

for Vitorond

with rated output 630 to 1080 kW

VITOTRANS 300

5692 790 GB 1/2009

Please keep safe.

Please follow these safety instructions closely to prevent accidents and mate-

rial 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 envi-

ronmental pollution.

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 elec-

trician.

■ The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following when working on

this system

■ all legal instructions regarding the pre-

vention of 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 (Northern Ire-

land),

– the Water Fittings Regulation or

Water Bylaws in Scotland,

– the current I.E.E. Wiring Regula-

tions.

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical appli-

ances 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 build-

ing.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 790 GB

If you smell flue gas

Danger

Flue gas can lead to life-threat-

ening 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 sup-

ply 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 unau-

thorised reconnection.

Please note

Electronic modules can be dam-

aged by electro-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 been tested together

with the heating system can com-

promise its function. Installing

non-authorised components and

non-approved modifications/con-

version can compromise safety

and may invalidate our warranty.

For replacements, use only orig-

inal spare parts from Viessmann

or those which are approved by

Viessmann.

Safety instructions

(cont.)

5692 790 GB

Commissioning, inspection, maintenance

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

Further details regarding the individual steps....................................................... 6

Parts lists............................................................................................................ 16

Commissioning/service reports........................................................................ 21

Certificates

Declaration of Conformity..................................................................................... 22

Index

5692 790 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

•

1. Matching the setting of the boiler control unit............ 6

•

2. Checking the connections of the neutralising

equipment and filling with neutralising agent

•

3. Checking system pressure and commissioning the

system

•

4. Readjusting the burner (only when retrofitting the

heat exchanger).............................................................. 6

• •

5. Shutting down the boiler system.................................. 6

• • •

6. Visually inspecting the gaskets on the inspection

cover and flue gas collector.......................................... 7

•

7. Cleaning the heating surfaces....................................... 10

•

8. Replacing damaged gaskets......................................... 14

• • •

9. Assembly in reverse order

• • •

10. Checking the water quality............................................ 14

• • •

11. Checking neutralising equipment as per the

manufacturer's instructions and replacing used

neutralising agent

• • •

12. Restarting the boiler

• • •

13. Filling in the service report for commissioning/

maintenance.................................................................... 15

•

14. Operating and service documents................................ 15

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 790 GB

Matching the setting of the boiler control unit

Make the setting according to the infor-

mation in chapter "Additional informa-

tion, Coding" in the service instructions

for the control unit.

Readjusting the burner (only when retrofitting the heat

exchanger)

Burner service instructions

Shutting down the boiler system

Switch OFF/isolate the main isolator

(outside the boiler room) and safeguard

against unauthorised reconnection.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 790 GB

Visually inspecting the gaskets on the inspection cover and flue

gas collector

Top panel

Thermal insulation mat

Gauze mat

Inspection cover

Gasket

Condensate drain

Lower flue pipe (flue gas outlet)

Connection collar

Note on

Not when commissioning

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Connection collar

Upper flue pipe (flue gas inlet)

Gauze jacket for flue gas collector

Thermal insulation jacket for flue

gas collector

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Upper flue gas collector

Gasket

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Cleaning the heating surfaces

Top panel

Thermal insulation mat

Gauze mat

Inspection cover

Gasket

Lower flue pipe (flue gas outlet)

Connection collar

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

With visible contamination:

Connection collar

Upper flue pipe (flue gas inlet)

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Gauze jacket for flue gas collector

Thermal insulation jacket for flue

gas collector

Upper flue gas collector

Gasket

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Turbulators

Heating surfaces

Condensate tray

Note on

Check condition of turbulators.

Note on

Clean heating surfaces thoroughly with

a water hose.

Note on

If heavily contaminated, wipe conden-

sate tray and clean thoroughly with a

water hose.

Please note

Prevent components that come

into contact with flue gas from

being scratched or otherwise

damaged.

Never use a wire brush or

sharp objects.

Prevent components that come

into contact with flue gas from

contact with pure iron, as corro-

sion damage can result. Use

plastic brushes if required.

For normal cleaning, rinse the heating

surfaces with a water jet.

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

However, you may use cleaning agents

if you notice stubborn residues, surface

discolouration or soot deposits.

For this, observe the following:

■ Only use solvent-free cleaning agents.

Ensure that cleaning agent never gets

between the heat exchanger and the

thermal insulation.

■ Remove soot deposits with alkaline

agents containing surfactants (e.g.

Fauch 600

■ Combustion residues may create thin,

yellow-brown surface discolouration

as well as hard deposits that may also

only become visible after removing the

soot deposits.

Use slightly acidic, chloride-free clean-

ing agents based on phosphoric acid

to remove surface discolouration and

hard deposits (e.g. Antox 75 E

■ Remove loose deposits from the heat

exchanger; rinse the heating surfaces

and flue gas collector thoroughly with

a water jet.

Danger

Cleaning agents can irritate the

skin and eyes.

Wear goggles, protective gloves

and protective clothing if

required.

Cleaning agent manufacturer's

details.

Replacing damaged gaskets

Before fitting new gasket E to the

inspection cover (see page 10) and gas-

ket

to the flue gas collector (see

page 12), clean sealing faces.

Checking the water quality

Boiler service instructions

Manufacturer:

Hebro Chemie GmbH

Rostocker Straße 40

D -41199 Mönchengladbach

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

Filling in the service report for commissioning/maintenance

You will find the service report on

page 21.

Operating and service documents

1. Complete and detach the customer

registration card:

■ Hand the section for system users

to the user for safekeeping.

■ Retain the section for contractors.

2. File all parts lists, operating and serv-

ice instructions in the folder and hand

this over to the system user.

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5692 790 GB

When ordering spare parts:

Quote the part no. and serial no. (see

type plate), as well as the position num-

ber of the individual part (as per this parts

list).

Obtain standard parts from your local

supplier.

Parts

001

Upper flue gas collector

003 Upper cleaning cover

004 Upper cleaning cover packing 140

x 180

005 Packing 12 x 16 x 3000

007

Flange C 100

009

Gasket NW 100

011

Lower flue gas collector

013 Turbulator

014 Flue gas high limit safety cut-out

120 °C

200 Upper gauze mat

201 Gauze jacket for flue gas collector

202 Thermal insulation jacket

203 Thermal insulation jacket for flue

gas collector

204 Upper thermal insulation mat

205 Mounting bracket

206 Rail

207 Lower flue pipe side panel

208 Lower flue pipe cover panel

209 Side panel, return

210 Cover panel flanged aperture

211 Side panel

212 Central side panel

213 Side panel, flow

214 Upper flue pipe side panel

215 Upper flue pipe cover panel

216 Top panel

217 Central side panel

Parts not shown

002

Upper flue gas collector

006 Toggle fastener

008

Flange C 125

010

Gasket NW 125

012

Lower flue gas collector

300 Touch-up spray, Vitosilver

301 Touch-up paint stick, Vitosilver

302 Thermal insulation pack

303 Installation instructions

304 Service instructions

Type plate, optionally on the r.h. or

l.h. side

With AWT size 5

With AWT size 6

Parts lists

5692 790 GB

216

215

214

212

213

212

211

208

211

209

212

210

217

207

Parts lists

(cont.)

5692 790 GB

205

206

205

206

205

Parts lists

(cont.)

5692 790 GB

202

203

201

200

204

Parts lists

(cont.)

5692 790 GB

005

001

004

003

013

009

007

009

007

011

Parts lists

(cont.)

5692 790 GB

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Viessmann VITOTRANS 300 Service Instructions Manual

Viessmann VITOTRANS 300 Service Instructions Manual

Viessmann VITOTRANS 300 Service Instructions Manual

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