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Installation and
Service Instructions
for use by engineers and heating contractors
Vitoflex 300-RF 150, 220, 300, 400 and 540
Wood-fired Boiler
Output range: RF 150 154 - 512 MBH (45- 150 kW)
RF 220 205 - 751 MBH (60- 220 kW)
RF 300 273 - 1024 MBH (80- 300 kW)
RF 400 341 - 1365 MBH (100- 400 kW)
RF 540 478 - 1843 MBH (140- 540W kW)
Vitoflex 300-RF
5603 878 - 04
03/2017
IMPORTANT
Please ensure that these instructions are
read and understood before commencing
installation and start-up. Failure to comply
with these Installation Instructions will
render all warranties null and void.
Working on the equipment
The installation, adjustment, service and
maintenance of this product must be
performed by a licensed professional heating
contractor, who is qualified and
experienced in the installation, service
and maintenance of hot water heating
boilers. There are no user serviceable
parts on the boiler or control.
Ensure main power supply to equipment,
the heating system and all external
controls has been deactivated.
Take precautions in all instances to avoid
accidental activation of power during
service work.
Improper installation, service or
maintenance can cause product/property
damage, severe personal injury, and/or
loss of life.
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
.
for future reference
Please file in Service Binder
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Summary of Contents for Viessmann Vitoflex RF 150
- Page 1 Installation and Service Instructions for use by engineers and heating contractors Vitoflex 300-RF 150, 220, 300, 400 and 540 Wood-fired Boiler Output range: RF 150 154 - 512 MBH (45- 150 kW) RF 220 205 - 751 MBH (60- 220 kW) RF 300 273 - 1024 MBH (80- 300 kW) RF 400 341 - 1365 MBH (100- 400 kW) RF 540 478 - 1843 MBH (140- 540W kW)
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Page 2: Safety, Installation And Warranty Requirements
“Safety” section. All inhabitants and destructive to Viessmann equipment. products of combustion must be safely vented to the outdoors. For a listing of chemicals which... -
Page 3: About These Instructions
This symbol indicates that other instructions must be referenced. Note: Viessmann Manufacturing Company Inc. reserves the right to make product changes or updates without notice and will not be held liable for typographical errors or omissions in the product... -
Page 4: Table Of Contents
Table of Contents Vitoflex 300-RF Installation & Operating Page Introduction Safety, Installation and Warranty Requirements....2 About These Instructions..........3 General Information Important Regulatory and Installation Requirements ..6 Codes..............6 Mechanical room...........6 Working on the equipment........6 Technical literature..........6 Product Information.............7 Boiler Description............8 Transport and Installation..........9 Delivery Condition.............10 Standard delivery condition........10 Special delivery condition........11... - Page 5 Table of Contents Vitoflex 300-RF Installation & Operating Page Mechanical (continued) Fire Extinguishing Systems........36 Fire extinguishing system for the in-feed auger..36 Fire extinguishing system for the conveyor auger..36 Fire extinguishing system for the down pipe....36 Assembly of the Fire Extinguishing Systems....37 Electrical Control Panel............38 Mounting of the control panel........38...
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Page 6: General Information
Leave all literature at the installation site and advise Literature applicable to all aspects of the Vitoflex 300-RF the system operator/ultimate owner where the wood-fired boiler: literature can be found. Contact Viessmann for - Installation and Operating Instructions additional copies. - Service and Maintenance Instructions ... -
Page 7: Product Information
General Information Vitoflex 300-RF Installation & Operating Product Information Maximum allowable working pressure (water)...30 or 60 psi Viessmann solid-fuel boiler may only be installed and serviced by trained personnel. Maximum water temperature…..250°F (120°C) (closed loop) Steel wood-fired hot water heating boiler. -
Page 8: Boiler Description
General Information Vitoflex 300-RF Installation & Operating Boiler Description Boiler Description Description Supplied with: The Vitoflex 300-RF Rotating Combustion System (pat- - Boiler with rotary heat exchanger including supply and ent no: EP 0 905 442 B1) was developed for automatic return temperature sensors combustion wood, pellets and wood chips to max. -
Page 9: Transport And Installation
General Information Vitoflex 300-RF Installation & Operating Transport and Installation IMPORTANT Precautions must be taken to avoid accidents and injury during the transportation of the boiler. Only hoist the boiler when it is entirely empty of water, fuel and ash. Lifting A number of lifting lugs will be provided on each boiler and heat exchanger where lifting gear may be attached. -
Page 10: Delivery Condition
General Information Vitoflex 300-RF Installation & Operating Delivery Condition Standard delivery condition The standard delivery condition of the Vitoflex 300-RF boiler includes pre-assembled components as well as components that need to be assembled by the contractor in the field. Components that are attached to the boiler at time of delivery: - The heat exchanger is mounted to the combustion chamber - Boiler is fully bricked - Boiler door is mounted to the heat exchanger including secondary air rotating blower... -
Page 11: Special Delivery Condition
General Information Vitoflex 300-RF Installation & Operating Delivery Condition (continued) Special delivery condition (partially disbanded) For special circumstances like restricted space to bring the boiler into the heating room, the size of the boiler can be reduced by detaching additional components to the ones as described in section “Standard delivery condition”. The assembly of these components require additional assembly time of approximately 6 hours. -
Page 12: Wood Fuel Requirements
The Vitoflex 300-RF is only suitable for burning fuels IMPORTANT listed in this section. A prerequisite for approval is of a fuel by Viessmann is the If different fuels are used, Viessmann will not assume approval for the fuel by the responsible public authorities. -
Page 13: Maximum Water Content
General Information Vitoflex 300-RF Installation & Operating Wood Fuel Requirements (continued) Maximum water content The maximum allowable water content of the fuel for Vitoflex 300-RF systems is limited to 35%. The water content impacts the maximum boiler output. Non-wood fuels Non-wood fuels, even if consisting of biomass, such as needles, foliage, grain, straw, fruit pits, etc., are unsuited as fuel for boiler operation and may not be used. -
Page 14: Content Limits For Non-Combustable Substances
General Information Vitoflex 300-RF Installation & Operating Wood Fuel Requirements (continued) Content limits for non-combustible substances - No wood fuels may contain any foreign bodies, such as pieces of metal, stones, masonry remnants or plastics. The following limits (per lb/kg of dry fuel) of contained non-combustible substances apply [ash analyzed at a temperature of 1500°F (815°C)]: Substance Limit... -
Page 15: Safety
Failure Note: Viessmann does not test any detectors and makes to heed this warning can cause property damage, no representation regarding any brand or type of severe personal injury, or loss of life. -
Page 16: Hazardous Materials
Safety Vitoflex 300-RF Installation & Operating Hazardous Material Fiberglass wool and ceramic fiber materials First aid measures - If eye contact occurs, flush eyes with water to remove dust. If symptoms persist, seek medical attention. WARNING - If skin contact occurs, wash affected areas gently with Inhaling of fiberglass wool and/or ceramic fiber materials soap and warm water after handling. -
Page 17: Power Failure Provision
Safety Vitoflex 300-RF Installation & Operating Power Failure Provision Customers must ensure that there is a supply of water independent of the electrical supply. This design ensures that in case of a power failure, the boiler will be reliably cooled by the thermal safety flush valve. Backup power supply or backup generator is highly recommended to ensure continious operation in the event of power failure. -
Page 18: Mechanical Room
The load-bearing capacity of the floor in Viessmann recommends the installation of an additional the area of the boiler bearing surface must be 512 lb/ft² electrical disconnect switch and a fuel shut-off valve (if (2500 kg/m²). -
Page 19: Mechanical Room Conditions
Safety Vitoflex 300-RF Installation & Operating Mechanical Room (continued) IMPORTANT WARNING Components which are not tested with the heating system Incorrect ambient conditions can lead to damage to the may damage the heating system or affect its functions. heating system and put safe operation at risk. Installation or replacement may only be carried out be a qualified heating contractor. -
Page 20: Combustion Air Supply
Safety Vitoflex 300-RF Installation & Operating Combustion Air Supply Confined spaces Codes When a furnace or boiler is enclosed in a space that has Provision for combustion and ventilation air must be made a volume less than 20% of that to be heated by the in accordance with applicable local codes. -
Page 21: Mechanical
Mechanical Vitoflex 300-RF Installation & Operating Technical Data Boiler model RF 150 RF 220 RF 300 RF 400 RF 540 Maximum output MBH (kW) 512 (150) 751 (220) 1024 (300) 1365 (400) 1843 (540) Minimum output MBH (kW) 154 (45) 205 (60) 273 (80) 341 (100) -
Page 22: Boiler Dimensions
Mechanical Vitoflex 300-RF Installation & Operating Boiler Dimensions BR Boiler Return BS Boiler Supply Dimensions Boiler Model RF- in. (mm) (392) 16 (406) 16 (406) 18e (466) 18e (466) 7 / 16 in. (mm) 60f (1541) 60 (1525) (1875) (1800) (2030) 13 / 16 7 / 8... - Page 23 Mechanical Vitoflex 300-RF Installation & Operating Boiler Dimensions (continued) Legend A Boiler Return B Boiler Supply C Automatic de-ashing system (optional) Dimensions Boiler Model RF- in. (mm) (3415) (3685) 119b (3035) 120b (3059) 136d (3457) 7 / 16 1 / 16 in.
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Page 24: Boiler Components
Mechanical Vitoflex 300-RF Installation & Operating Boiler Components Legend A Pneumatic cleaning system (optional) B Cleaning cover, flue gas collector, alternate port for the flue gas exhaust blower C Cover with sight glass D Recirculation gas line, line routing variable E Igniter F Rotary blower G Flue gas temperature sensor... -
Page 25: Recirculation System
Mechanical Vitoflex 300-RF Installation & Operating Recirculation System Legend A Vent piece with recirculation adaptor B Recirculation system damper C Threaded rod M12 39e in. (1000 mm) D Base plate M12 (x4) E Pipe clamp M12 (x4) F Pipe clamp fitting (x16) G Elbow 15º... -
Page 26: Chimney Connection
Mechanical Vitoflex 300-RF Installation & Operating Chimney Connection It is recommended to install a draft damper in the chimney The draft damper is field supplied. The optional draft damper can be installed in the flue gas pipe of the biomass boiler The draft damper should be installed in the flue gas pipe as close as possible to the chimney not closer than 39e in. -
Page 27: Flue Gas Cyclone
Mechanical Vitoflex 300-RF Installation & Operating Flue Gas Cyclone The flue gas cyclone minimizes dust emissions and is Supplied with: designed as a multi cyclone with axial function. The 1 flue gas cyclone ■ de-duster is fully insulated and has three covers for 1 ash container 24 USG (90 L) ■... -
Page 28: Metal Mesh Filter
Mechanical Vitoflex 300-RF Installation & Operating Metal Mesh Filter The metal mesh filter removes dust and fine dust from the Supplied with: flue gas. It is characterized by a particularly high degree - Two-part, insulated filter casing with: of separation. This ensures a fine dust content of less - Hinged doors, lockable by means of a quick-action than 20 mg/Nm in the clean gas. - Page 29 Mechanical Vitoflex 300-RF Installation & Operating Metal Mesh Filter (continued) Legend A Clean gas collector B Crude gas distributor (connection possible on both sides) C Recirculation gas connection D Clean gas to chimney E Crude gas from boiler (connection possible on both sides) F Flue gas exhaust blower (with variable rotation) (alternate mounting of flue gas blower shown in dark grey) G Control panel Ecotronic...
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Page 30: Safety Devices
Mechanical Vitoflex 300-RF Installation & Operating Safety Devices Boiler system with return 3-way mixing valve 1. Install the pressure relief valve, discharge pipe, air vent and pressure gage as illustrated in section piping To reliably prevent boiler corrosion through condensation and installation of safety devices. - Page 31 Mechanical Vitoflex 300-RF Installation & Operating Safety Devices (continued) The safety equipment for the heating installation must be installed by the heating contractor authorized to do so. Legend L Safety heat exchanger connections, NPTM b in. A Nipple, c in. x 1b in. M Sensor well - fixed high limit B Reducing coupling, c in.
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Page 32: Piping And Installation Of Safety Devices
Mechanical Vitoflex 300-RF Installation & Operating Piping and Installation of Safety Devices System fill Drain inspection port System fill Safety heat exchanger top view 3-Way mixing valve System return line Blocked 2 heat exchanger port loops for Bypass line Vitoflex 300-RF 400/540 Valve adjustment must be facing forward... - Page 33 - PDP pressure relief valve drain pipe be below 150°F (65°C). - DCW Cold water inlet, min. 36 psi (2.5 bar), max. A Viessmann sized boiler pump with a boiler 51 psi (3.5 bar) 3-way mixing valve are provided according to the - AV Air separator / vent tables below.
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Page 34: Fire Protection
RF 300 3 in. 3-way mixing valve RF 400 3 in. 3-way mixing valve RF 540 4 in. 3-way mixing valve Viessmann ASME recommended tank sizes (U-stamped) Boiler model Tank size RF 150 1514 RF 220 2006 RF 300 2650... -
Page 35: Back-Burn Safeguard For The Fuel Supply System
Fire protection for fuel storage space unit and the boiler. The rotary valve is suited to reduce Viessmann does not provide fire protection for the fuel pressure and at the same time is considered a suitable storage space. -
Page 36: Fire Extinguishing Systems
Mechanical Vitoflex 300-RF Installation & Operating Fire Extinguishing Systems The fire extinguishing system functions independent from Fire extinguishing system for the conveyor auger the electrical power and is flooding the material which is Note: The fire extinguishing system for the conveyor still remaining in the in-feed auger in case of a back-burn. -
Page 37: Assembly Of The Fire Extinguishing Systems
Mechanical Vitoflex 300-RF Installation & Operating Assembly of the Fire Extinguishing System deburr drill hole Connection to the extinguishing water container or cold water supply piping (field supplied). Item No. Quantity Description Item No. Quantity Description Connector b in. Floater switch (N1) Danfoss AVTA Washer Reducer c in. -
Page 38: Control Panel
(10°C). In case of doubt, preference should be given to placing the control panel outside the mechanical room The Viessmann supplied field wiring diagram is not a near the heating room door. complete system drawing. It is the installer’s responsibility... - Page 39 Electrical Vitoflex 300-RF Installation & Operating Control Panel (continued) Device tags and designations may vary from project to project. Please refer to the field wiring diagram for details. The wiring diagram will be supplied after the control panel is built or with the receipt of the control panel. Vitocontrol-C, Ecotronic RF Components installed in the control panel Device tag Description...
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Page 40: Electrical Components
Electrical Vitoflex 300-RF Installation & Operating Electrical Components (Hidden) (Hidden) (Hidden) 10, 11 10, 11 Note: Items 30, 32 are not illustrated. 8, 9 8, 9... - Page 41 Electrical Vitoflex 300-RF Installation & Operating Electrical Components (continued) Component overview B Sensors M Hight voltage S Switches Y Low voltage N Sensors High voltage Number Designation Device tag Description -14M1 Flue gas exhaust blower -27M2 Grate drive -28M3 Rotary blower -8M4 De-ashing auger -8M5...
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Page 42: Fuel Transport And Extraction Systems
Electrical Vitoflex 300-RF Installation & Operating Fuel Transport and Extraction Systems Rotary Valve Number Designation Device tag Description -9 M9 Motor for rotating valve... -
Page 43: In-Feed Auger
Electrical Vitoflex 300-RF Installation & Operating Fuel Transport and Extraction Systems In-feed auger Number Designation Device tag Description -11M31 Motor for in-feed auger S31.1 -11S31.1 Limit switch for maintenance lid B31.1 -11B31.1 Light barrier metering container (Transmitter) B31.2 -11B31.2 Light barrier metering container (Receiver) Y30.1 -23Y30.1 Slide valve T30... -
Page 44: Pellet Extraction Auger
Electrical Vitoflex 300-RF Installation & Operating Fuel Transport and Extraction Systems (continued) Pellet extraction auger Number Designation Device tag Description -12M32 Motor for pellet extraction auger S32.1 -12S32.1 Limit switch for maintenance lid S32.2 -12S32.2 Limit switch for silo door (not shown) Note: For details on designation, see field wiring diagram. -
Page 45: Horizontal Extraction System
Electrical Vitoflex 300-RF Installation & Operating Fuel Transport and Extraction Systems (continued) Horizontal extraction system Number Device tag Device tag Description -12M32 Motor for extraction auger -12M33 Motor for agitator -12B32 Light barrier for extraction auger S32.1 -12S32.1 Safety switch for maintenance lid S32.2 -12S32.2 Safety switch for silo door (not shown) -
Page 46: Walking Floor Auger
Electrical Vitoflex 300-RF Installation & Operating Fuel Transport and Extraction Systems (continued) Walking floor auger Number Designation Device tag Description -6M3 Motor for walking floor auger -68S3 Safety switch for maintenance lid S3.1 -68S3.1 Safety switch for auger cover B3/1 -61B3/1 Light barrier walking floor auger (Transmitter) B3/2... -
Page 47: Thermal Storage Tank
Electrical Vitoflex 300-RF Installation & Operating Thermal Storage Tank Silo Lid Number Designation Device tag Description Y6.3 -22Y6.3 Solenoid valve silo lid open Y6.4 -22Y6.4 Solenoid valve silo lid close S6.1 -22S6.1 Key operated switch for silo lid M901 -24M901 Vibration motor 1 M902 -24M902... -
Page 48: Boiler Wiring
Boiler Wiring CAUTION CAUTION The Viessmann supplied field wiring diagram is not a The information about wire type, wire number and wire complete system drawing. It is the installer’s responsibility gauge made in the wiring diagrams is not obligatory. The... -
Page 49: Commissioning
Commissioning Initial start up Water quality Only a Viessmann or another trained specialist may put Treatment for boiler feed water should be considered a newly installed system into operation for the first time. in areas with known problems, such as where a high Before the system is commissioned, the system must be mineral content and hardness exist. -
Page 50: Operation
Note: Viessmann recommends the installation of carbon monoxide detector(s) inside the fuel storage area. Heating system not in operation: - If the articulated arms or spring-mounted plates are still IMPORTANT covered by fuel, refilling can be carried out immediately. -
Page 51: Excess Conditions
Operation Vitoflex 300-RF Installation & Operating Excess Conditions Low water/excess water pressure IMPORTANT Possible causes: - Low water: Leakage in the heating system. Excess temperature/power failure - Excess water pressure: The expansion tank is not functioning. CAUTION In either case, the boiler should be examined by a qualified DANGER OF THIS EQUIPMENT SUDDENLY GOING UP heating contractor. -
Page 52: Operating The Boiler
Operation Vitoflex 300-RF Installation & Operating Operating the Boiler Heating up Switching off - Press the F1 key “Vitoflex 300-RF Wood”. The loader - Press the F1 “Vitoflex 300-RF Wood”. As feedback to modules will be switched on in the appropriate order. this, “Run Auger Empty”... -
Page 53: Ecotronic Control System
The ECOTRONIC facility control system is a decentralized Switch WOOD operation on and off microprocessor system (CAN-BUS) developed by Viessmann with various modules that are connected by F2 (Vitoflex 300-RF Oil) a data transmission line. Switch OIL operation on and off (not applicable to... -
Page 54: Mmc Software Update
■ Disconnect the power supply, wait for approx. 5 seconds. ■ Connect the power supply. ■ Disconnect the MMC-dongle approximately 5 seconds after the control has booted up. (Please return the MMC dongle as quickly as possible to Viessmann). Data transfer Buffer battery button... -
Page 55: 1.0 Operating The Ecotronic
Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 1.0 Operating the ECOTRONIC Menu designation Scrolling Screen and description number symbols Cursor keys Change target values Red/green LED Function keys Display of the activated menu (e.g.: Vitoflex 300-RF parameter) Menu designation: In addition, an activated menu is also indicated by the flashing green LED of the respective function key. -
Page 56: 4.0 Vitoflex 300-Rf Eco Parameters
Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 4.0 Vitoflex 300-RF ECO parameters Green LED - flashes with an active menu Red LED - illuminates with excess temperature fault or Vitoflex 300-RF fault 4.1 Parameters menu Menu designation - Vitoflex 300-RF parameter Access menu - Press F3 briefly Exit menu:... - Page 57 Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 4.1 Parameters menu (continued) Screen number Screen text Parameter description Factory setting (14) Automatic operation Up to which temperature sensor should the thermal Lower Accumulator load to storage tank be loaded in wood operations temperature sensor Only display if:...
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Page 58: 4.2 Service Menu
Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 4.2 Service Menu Menu designation: - Vitoflex 300-RF service Access menu: - Hold down O, press F3 briefly Exit menu: - Press F3 briefly or automatically after 60 seconds Note: Depending on the design and setting, some menus and text do not appear. Screen number Screen text Parameter description Factory setting... - Page 59 Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 4.2 Service Menu (continued) Screen number Screen text Parameter description Factory setting (41) Ember monitoring system Delay ember bed light barriers until in-feed auger stops 30 sec Switch-off delay (in-feed auger operating time is monitored) Target (42) In-feed auger...
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Page 60: 5.0 Vitoflex 300-Rf Eco Loading
Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 5.0 Vitoflex 300-RF ECO loading Green LED - flashes with an active menu Red LED - illuminates with loading fault 5.1 Loading menu Menu designation: - Loading Access menu: - Press F4 briefly Exit menu: - Press F4 briefly or automatically after 60 seconds Note: Depending on the design and setting, some menus and text do not appear. -
Page 61: 5.2 Loading Service Menu
Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 5.1 Loading menu (continued) Screen number Screen text Parameter description Factory setting (41) Extraction system 2 Switch-on delay of the extraction system 2 3 sec ..(e.g. spring extraction system, pellet extraction auger) delay Only display if: Extraction system 2 available... - Page 62 Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 5.2 Loading Service Menu (continued) Screen number Screen text Parameter description Factory setting Feed system 1 Delay of the conveying equipment 1 light barrier 500 ms ..(e.g. in-feed auger 1) light barrier delay Only display if:...
- Page 63 Operation Vitoflex 300-RF Installation & Operating ECOTRONIC Control System (continued) 5.2 Loading Service Menu (continued) Screen number Screen text Parameter description Factory setting (41) Extraction system 2 Reversing interval extraction system 2 240 sec ..Preferred direction YES: The extraction is reversed in reversing interval the event of an overload (current measurement) for the duration of the reversing interval.
- Page 64 Vitoflex 300-RF Installation & Operating...
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