Viessmann Vitoflex 300-RF Service And Maintenance Instructions
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Viessmann Vitoflex 300-RF Service And Maintenance Instructions

Wood-fired boiler
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Service and
Maintenance 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 to 512 MBH (45 to 150 kW)
RF 220 205 to 751 MBH (60 to 220 kW)
RF 300 273 to 1024 MBH (80 to 300 kW)
RF 400 341 to 1365 MBH (100 to 400 kW)
RF 540 478 to 1843 MBH (140 to 540 kW)
Vitoflex 300-RF
5797 342 - 01
08/2017
H
WARNING
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
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
WARNING
Improper installation, adjustment and/or
operation could cause carbon monoxide
poisoning resulting in injury or loss of 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.
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 300-RF

  • Page 1 Service and Maintenance 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 to 512 MBH (45 to 150 kW) RF 220 205 to 751 MBH (60 to 220 kW)

  • Page 2: Safety, Installation And Warranty Requirements

    Introduction Vitoflex 300-RF Service & Maintenance Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing service and/or maintenance. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.

  • Page 3: About These Instructions

    Introduction Vitoflex 300-RF Service & Maintenance About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.  Indicates an imminently hazardous situation which,...

  • Page 4: Table Of Contents

    Table of Contents Vitoflex 300-RF Service & Maintenance Page Introduction Safety, Installation and Warranty Requirements....2 About these Instructions..........3 General Information Product Information.............5 Important Regulatory and Installation Requirements ..6 Safety Safety Instructions............8 Carbon Monoxide............9 Extreme Weather Conditions........10 Hazardous Material............11 Mechanical Room.............12 Combustion Air Supply..........13...

  • Page 5: Product Information

    General Information Vitoflex 300-RF Service & Maintenance Product Information Viessmann solid-fuel boiler can only be installed and Maximum allowable working pressure (water) ..30 or 60 psi serviced by qualified trained personnel. Maximum water temperature ..250°F (120°C) (closed loop) Steel wood-fired hot water heating boiler.

  • Page 6: Important Regulatory And Installation Requirements

    Technical literature  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.
  • Page 7 General Information Vitoflex 300-RF Service & Maintenance Important Regulatory and Installation Requirements (continued) Regular maintenance and service WARNING The entire heating system must be cleaned and serviced on a regular basis by a qualified contractor or service Improper installation, adjustment, service or maintenance agency to ensure reliable, energy-efficient, and can cause flue products to flow into living space.

  • Page 8: Safety Instructions

    Power supply: 120/1/60 VAC and 240/1/60 VAC. operated and maintained properly. In case of an emergency, the Vitoflex 300-RF can be disconnected from the electrical power supply at all the IMPORTANT leads by the main switch on the control cabinet.

  • Page 9: Carbon Monoxide

    Note: Viessmann does not test any detectors and makes no representation regarding any brand or type of detector. WARNING...

  • Page 10: Extreme Weather Conditions

    Safety Vitoflex 300-RF Service & Maintenance Extreme Weather Conditions Frozen water pipe hazard Your heating boiler is designed to provide a warm and If the building will be unattended for an extended period comfortable living environment. It is NOT designed to of time during cold weather, you should...

  • Page 11: Hazardous Material

    Safety Vitoflex 300-RF Service & Maintenance Hazardous Material Fiberglass wool and ceramic fiber materials Suppliers of ceramic fiber products recommend the WARNING following first aid measures: - Respiratory tract (nose and throat) irritation: Inhaling of fiberglass wool and/or ceramic fiber materials If respiratory tract irritation develops, move the is a possible cancer hazard.

  • Page 12: Mechanical Room

    Safety Vitoflex 300-RF Service & Maintenance Mechanical Room No combustible materials may be stored in the heating IMPORTANT room. The heating boiler may only be set up on a fire- resistant and temperature-resistant floor. No temperature- Components which are not tested with the heating...

  • Page 13: Combustion Air Supply

    Safety Vitoflex 300-RF Service & Maintenance Combustion Air Supply Codes General Provision for combustion and ventilation air must be made This equipment requires fresh air for safe operation. in accordance with applicable local codes. The boiler location must never be under negative pressure.

  • Page 14: Components Of The Biomass Boiler

    Maintenance Vitoflex 300-RF Service & Maintenance Components of the Biomass Boiler Legend 1 In-feed auger with isolating layer 8 Boiler door 2 Drive for moving grate 9 Heat exchanger 3 Moving grate qP Rotary combustion chamber (Viessmann-patented) 4 Drive for automatic de-ashing system (optional)

  • Page 15: Cleaning

    Maintenance Vitoflex 300-RF Service & Maintenance Cleaning Boiler Regular cleaning and maintenance of the boiler system is The heat exchanger, flue gas pipe, and chimney must be of the utmost importance to assure trouble-free operation cleaned regularly to remove accumulated creosote and ash.

  • Page 16: Heat Exchanger Displacement Rods

    Maintenance Vitoflex 300-RF Service & Maintenance Cleaning (continued) Heat exchanger displacement rods The displacement rods improve the heat transmission in the heat exchanger and reduce the temperature of the exhaust gas, thus improving the efficiency of the heating system. They have to be taken out to clean the heat exchanger and put back in after cleaning.

  • Page 17: Pneumatic Cleaning System (Optional)

    Boiler Control system Heat exchanger: Even when the Vitoflex 300-RF is not in operation for long periods, the power supply to the control system should When the Vitoflex 300-RF is not in operation for a not be interrupted (do not turn off the main switch).

  • Page 18: Warning Message

    Troubleshooting Vitoflex 300-RF Service & Maintenance Warning Message 1. Eliminate the cause of the warning. 2. Acknowledge the warning message in the controller. Fault Message WARNING Risk of injury due to faults in the heating system that have not been rectified.
  • Page 19 Troubleshooting Vitoflex 300-RF Service & Maintenance Fault Message (continued) Fault message Cause Remedy Fault: High limit safety cut-out Setting for set supply Check the setting for the set supply temperature is too high temperature Faulty system component Check boiler circuit pump and...
  • Page 20 Troubleshooting Vitoflex 300-RF Service & Maintenance Fault Message (continued) Fault message Cause Remedy Fault: Temperature level, Loss of oil at the hydraulic unit - Check the fittings, lines and cylinders hydraulics, push floor for leaks - Top up the oil...
  • Page 21 Troubleshooting Vitoflex 300-RF Service & Maintenance Fault Message (continued) Fault message Cause Remedy Fault: Electrostatic filter Call up possible cause at Check and remedy the fault in electrostatic filter controller accordance with message on electrostatic filter controller Fault: Boiler supply sensor...
  • Page 22 Troubleshooting Vitoflex 300-RF Service & Maintenance Fault Message (continued) Fault message Cause Remedy Fault: Emergency stop actuated Emergency stop button is Reset emergency stop button engaged Fault: High limit safety cut-out, Fire in fuel store Notify fire service fuel store...
  • Page 23 Troubleshooting Vitoflex 300-RF Service & Maintenance Fault Message (continued) Warning messages Fault message Cause Remedy Warning: Transverse screw of Upper light barrier for Clean or replace the light barrier container X overfilled transverse screw is dirty sensors Shutdown delay of lower light...

  • Page 24: Adjusting The Fuel Supply And Air Supply

    Adjusting the Ash Removal The amount of ash in the combustion chamber depends on the ash content of the fuel. The Vitoflex 300-RF removes ash automatically by means of a moving grate. The intervals at which the grate is moved can be adjusted to individual requirements.

  • Page 25: Visual Inspection Of Combustion

    Troubleshooting Vitoflex 300-RF Service & Maintenance Visual Inspection of Combustion During operation, the controller controls, regulates and monitors all components and system parts automatically. CAUTION Risk of burns due to hot machine components. Only touch handles and identified parts. Never touch sight glasses or their retainers.

  • Page 26: Fault Messages

    Scanning Vitoflex 300-RF Service & Maintenance Fault Messages In the footer, tap on the button. The fault message screen opens up. Current fault messages This screen displays unprocessed fault messages. Display Description “Time/Date” Time at which the fault message occurred “Text”...

  • Page 27: Information On Maintenance

    Viessmann Technical Service Viessmann Technical Service Annual General Inspection Viessmann Technical Service is happy to carry out the inspection and maintenance of your heating system and can provide a quote for a maintenance contract. Contact the Technical Service department for an annual general inspection or if you wish to change fuel.

  • Page 28: Servicing The Boiler

    Maintenance Vitoflex 300-RF Service & Maintenance Servicing the Boiler Component, activity Interval Every 6 Annually hours hours months Boiler Service electrical safety equipment. Service safety equipment on the water side. Check the respective alignment of the transmitters and receivers of light barriers E.

  • Page 29: Cleaning The Boiler

    Maintenance Vitoflex 300-RF Service & Maintenance Servicing the Boiler (continued) Component, activity Interval Every 6 Annually hours hours months Heat exchanger B Check system pressure at pressure gauge (minimum pressure, water shortage). Check thermally activated safety valve for tightness. Ignition system F Check ignition pipe for blockages and clean if necessary.
  • Page 30 Maintenance Vitoflex 300-RF Service & Maintenance Cleaning the Boiler (continued) Component, activity Interval Annually hours hours hours Boiler Clean combustion chamber D and flue gas collector A plus entire flue gas path. Observe information on flue gas path. Combustion chamber D Open inspection cover G and check infeed grate F for contamination and slag deposits, clean if necessary.
  • Page 31 Maintenance Vitoflex 300-RF Service & Maintenance Cleaning the Boiler (continued) Component, activity Interval Annually hours hours hours Ash removal Without automatic ash removal: Open both cleaning hatches K and empty both ash pans. Cleaning the interior. With automatic ash removal (optional): Open cleaning hatch K and empty ash pan.

  • Page 32: Servicing The Flue Gas Dust Extrator (Optional)

    Maintenance Vitoflex 300-RF Service & Maintenance Servicing the Flue Gas Dust Extractor (optional) Note: Only operate the boiler with the ash box installed. Component, activity Interval 1200 Every 6 Annually hours hours months Flue gas fan A Disconnect plug on motor.

  • Page 33: Servicing The Conveyor Devices

    Maintenance Vitoflex 300-RF Service & Maintenance Servicing the Conveyor Devices WARNING Risk of serious or fatal injury through becoming trapped or crushed by moving parts. Before starting any maintenance work on the conveyor devices, switch OFF the heating system at the mains isolator. Safeguard the system against reconnection.
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This manual is also suitable for:

Vitoflex 150-rfVitoflex 220-rfVitoflex 400-rfVitoflex 540-rf

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