Viessmann Vitoladens 300-C Operating instructions

VIESMANN
Service instructions
for contractors
Vitoladens 300-C
Type VC3, 12.9 to 28.9 kW
Oil fired condensing boiler
with integral boiler control unit
For applicability, see the last page
VITOLADENS 300-C
5692 745 GB 7/2007 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental 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.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 745 GB

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
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 745 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 38
Code 2........................................................................................................ 41
Resetting codes to their delivered condition ................................................ 56
Service scans
Service level overview ............................................................................... 57
Temperatures, boiler coding card and brief scans ....................................... 58
Checking outputs (relay test) ...................................................................... 60
Scanning operating conditions and sensors ................................................ 61
Troubleshooting
Fault display ............................................................................................... 63
Fault codes ................................................................................................ 64
Repairs ...................................................................................................... 71
Function description
Control unit................................................................................................. 79
Control functions ........................................................................................ 80
Remote control DIP switches ...................................................................... 86
Designs
Connection and wiring diagram –internal connections ................................ 88
Parts lists .................................................................................................. 93
Specification............................................................................................. 104
Certificates
Declaration of conformity ............................................................................ 105
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 106
Keyword index .......................................................................................... 107
Index
4
Index
5692 745 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
!!!





















•01. Filling the heating system ................................................. 7
••• 02. Checking all connections on the heating water
side for leaks
•03. Venting the boiler .................................................................. 8
•04. Venting the heating system
• • 05. Draining the heating system (if required) .................... 9
•06. Filling the siphon or neutralising system
(accessory) with water ........................................................ 10
•07. Checking the power supply connection
• • 08. Setting the time and date (if required)........................... 11
•09. Changing the language at the control unit .................. 11
••• 10. Function sequence and possible faults ....................... 12
• • 11. Removing the front panel................................................... 14
• • 12. Adjusting the standard burner settings ....................... 14
• • 13. Adjusting the oil pressure and checking the
vacuum ..................................................................................... 16
• • 14. Adjusting the air volume (static burner pressure) . . . 17
•15. Cleaning the burner ............................................................. 18
•16. Replacing the nozzle and checking or adjusting
the ignition electrodes ........................................................ 19
• • 17. Cleaning and replacing the oil pump filter, if
required ................................................................................... 20
• • 18. Opening the boiler door...................................................... 21
• • 19. Cleaning the heating surfaces ......................................... 21
• • 20. Checking gaskets and thermal insulation
components ............................................................................ 24
• • 21. Closing the boiler door and fitting the front panel . . . 26
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 745 GB

Commissioning steps
Inspection steps
Maintenance steps Page
!!!





















• • 22. Checking the condensate drain and cleaning the
siphon (if installed) .............................................................. 26
• • 23. Checking the neutralising system (accessories) ..... 26
• • 24. Checking the active charcoal filter (accessories) . . . . 27
••• 25. Checking the diaphragm expansion vessel and
system pressure
••• 26. Checking the burner (recording values on
page 102 of the commissioning/service report)
••• 27. Checking the function of all safety valves
••• 28. Checking the tightness of electrical connections
•29. Matching the control unit to the heating system ...... 27
•30. Adjusting the heating curves ........................................... 30
•31. Linking the control unit to the LON ................................ 34
•32. Instructing the system user .............................................. 36
•33. Scanning and resetting the "Service" display ........... 36
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 745 GB

Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water with hardness exceeding 3.0 mol/m
3
, e.g. using a
small softening system for heating water (see Viessmann Vitoset price
list).
&An antifreeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Remove front insulation shell A.
3. Open air vent valve B.
4. Fill the heating system at the fill
valve Cin the heating return.
(Minimum system pressure
0.8 bar.)
5. Close air vent valve Bwhen no
more air is being expelled.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 745 GB

6. Close boiler fill valve C.
Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Remove front insulation shell A(if
already fitted).
3. Connect the drain hose on air vent
valve Bwith a drain.
4. Open valves Band Cand vent
using mains pressure until no more
air noise is audible.
5. Close valves Band Cand open
the heating water shut-off valves.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 745 GB

Draining the heating system (if required)
ADrain valve
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 745 GB

Filling the siphon or neutralising system (accessory) with
water
ASiphon BNeutralising system (accessories)
Pull the supply hose from the boiler
and fill with a little water.
Neutralising system operating instructions
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 745 GB

Setting the time and date (if required)
Note
&During commissioning, or after a
prolonged time out of use, it may be
necessary to reset the time and
date, if the time flashes in the dis-
play.
&When the unit is first taken into
operation the display is in German
(default language setting):
Time (see step 1)
Date (see step 2)
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Date" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Changing the language at the control unit
Note
When the unit is first taken into opera-
tion the display is in German (default
language setting):
Select heating circuit (see step 1.)
Outside temperature (see step 3.)
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 745 GB

3. cpress this button again,
"Außentemperatur" (outside
temperature) is displayed.
4. bfor the required language.
5. dto confirm.
Function sequence and possible faults
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Yes
Oil preheating
starts No
after approx.
10 min
Check the oil pre-
heater, cables
and plug-in con-
nectors
Fault
E6
Yes
Fan starts after
no more than
10 min.
Green LED on
ignition transfor-
mer flashes.
No Fault Check the oil pre-
heater, fan,
cables and plug-
in connectors
(the oil preheater
has not switched
through; the tem-
perature is not
achieved)
F9
Yes
The air pressure
switch responds No After approx. 51 s Check the air
pressure switch,
cables and plug-
in connectors
Fault
F5
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 745 GB

Yes
Ignition and oil
pump motor start No Check the ignition module and oil
pump motor,
cables and plug-
in connectors
Yes
The solenoid
valves open No Fault Check the oil sup- ply; check the so-
lenoid valves
F4
Yes
Flame signal pre-
sent
Symbol A
No Fault Check ignition
electrodes, elec-
trode gaps and
connecting lines
F4
Yes
Burner in opera-
tion.
Green LED on
ignition transfor-
mer is perma-
nently on.
For further details regarding faults,
see page 64.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 745 GB

Removing the front panel
Adjusting the standard burner settings
Standard burner settings
Note
Check that the service instructions are valid for the relevant burner (see applic-
ability on the last page and the serial no. on the boiler type plate).
AFlue gas test port
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 745 GB

Rated output kW 12.9/19.3 16.1/23.5 19.3/28.9
Burner stage 1 2 1 2 1 2
Rated output kW 12.9 19.3 16.1 23.5 19.3 28.9
Oil burner nozzle Type 80°H LE V 80°H LE V 80°H LE
Make: Danfoss Gph 0.40 0.50 0.50
Oil pressure ap-
prox. *1bar 8-10.5 17-20 10-13 19-22 13.6 27
Max. permissible
vacuum
in the oil feed line
bar 0.35 0.35 0.35 0.35 0.35 0.35
Oil throughput kg/h 1.05 1.58 1.45 1.92 1.33 2.00
approx. l/h 1.24 1.86 1.71 2.26 1.57 2.36
Static burner
pressure approx.
mbar 7.5-
10.5
18-21 10-13 18-21 10.3 21.9
CO2content ap-
prox.
% 12.2-13.2 12.2-13.2 13.2 13.5
Nozzle gap "a" mm 3.0
+0.2/-0.3
1.5
+0.2/-0.3
1.5
+0.2/-0.3
(see page 19)
!Please note
An incorrectly adjusted nozzle gap "a" can result in irregular operation of
the burner and even a fault shutdown.
Always maintain the stated dimension and check in accordance with the
details on page 19.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 745 GB
*1Due to nozzle tolerances and varying oil characteristics, the oil pressure may vary from
the values shown.

Adjusting the oil pressure and checking the vacuum
Oil pump; make: Danfoss,
type BFP 52
1. Insert the pressure gauge (range
0 - 25 bar) into test port "P"D
and the vacuum gauge (range 0 -
1 bar) into test port "V"C.
Note
Seal the pressure and vacuum
gauges only with copper or alumi-
nium gaskets or with O-rings.
Never use tape to seal these
joints.
2. Start the boiler.
3. Press Kand dsimultaneously
for approx. 2 s.
"Relay test" is shown in the dis-
play.
After approx. 4 s the display
shows "Burner st 1 ON".
4. Where vacuum measures higher
than 0.35 bar, check the filter for
contamination or check the pipe
route.
5. If required, adjust the oil pressure
for stage 1 at pressure adjusting
screw Bof the oil pump (for
standard values, see page 15).
6. Check the actual emission values
after adjusting the oil pressure.
7. Select burner stage 2 with a.
"Burner st 1 + 2 ON" is shown on
the display.
8. If required, adjust the oil pressure
for stage 2 at pressure adjusting
screw Aof the oil pump.
9. Check the actual emission values
after adjusting the oil pressure.
10. After testing, press d.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 745 GB

Adjusting the air volume (static burner pressure)
1. Start the boiler.
2. Remove plug Afrom the test port.
3. Connect the U-shaped pressure
gauge to test port A.
4. Press Kand Fsimultaneously
until "Speed stage 1" and a value
between 1 and 255 are displayed.
5. Change the value with a/buntil
the static burner pressure dis-
played by the U-shaped pressure
gauge and the CO2flue gas con-
tent correspond to the values in the
table on page 15.
6. Confirm the set value with d.
Note
The control unit changes automati-
cally to burner stage 2. The display
shows "Speed stage 1 + 2 " and a
value between 1 and 255.
7. Repeat steps 4 and 5 for burner
stage 2.
8. Check the set values.
9. Seal test connector Aagain with
the previously removed plug.
Note
Do not seal the connector next to
test connector A.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 745 GB

Cleaning the burner
1. Undo nuts, remove the lid with
mixer equipment Aand secure in
the maintenance position.
2. Pull the leads off ignition electro-
des D.
3. Undo Allen screw Band remove
rifling facility C.
4. Clean the restrictor, dosing ring
and ignition electrodes.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 745 GB

Replacing the nozzle and checking or adjusting the ignition
electrodes
1. Undo nozzle Ewhilst holding the
oil preheater. Prevent the formation
of bubbles.
2. Insert a new LE nozzle E(whilst
holding the oil preheater).
Select the nozzle in accordance
with the details on page 15.
3. Insert rifling facility Cas far as
possible. Align ignition electrodes
Din accordance with the drilled
holes towards the cable entries.
Install the oil burner nozzle cen-
trally into the restrictor.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 745 GB

4. Secure Allen screw Bof the rifling
facility. Check nozzle gap "a".
!Please note
An incorrectly adjusted noz-
zle gap "a" can result in irre-
gular operation of the burner
and even a fault shutdown.
Rated output kW 12.9/19.3 16.1/23.5 19.3/28.9
Nozzle gap "a"
(see page 19) mm 3.0
+0.2/-0.3
1.5
+0.2/-0.3
1.5
+0.2/-0.3
Cleaning and replacing the oil pump filter, if required
Oil pump; make: Danfoss, type BFP 52
AFilter plug
BO-ring (replace)
CFilter (replace)
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 745 GB