Viessmann Vitoladens 300-C Operating instructions

Service instructions
for contractors
VIESMANN
Vitoladens 300-C
Type VC3, 12.9 to 28.9 kW
Oil condensing boiler
with integral boiler control unit
For applicability, see the last page
VITOLADENS 300-C
5692 774 GB 11/2009 Please keep safe.

2
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.
Note
Details identified by the word "Note" con-
tain 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 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
Safety instructions
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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
Safety instructions (cont.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Codes
Code 1.................................................................................................................. 37
Code 2.................................................................................................................. 40
Resetting codes to their delivered condition......................................................... 54
Service scans
Service level overview ......................................................................................... 55
Temperatures, boiler coding card and brief scans .............................................. 55
Checking outputs (relay test)................................................................................ 57
Scanning operating conditions and sensors ........................................................ 58
Troubleshooting
Fault display......................................................................................................... 60
Fault codes .......................................................................................................... 61
Repairs................................................................................................................. 68
Function description
Control unit........................................................................................................... 76
Control functions.................................................................................................. 77
Remote control DIP switches............................................................................... 83
Designs
Connection and wiring diagram – internal connections ....................................... 85
Parts lists............................................................................................................ 90
Commissioning/service reports........................................................................ 97
Specification....................................................................................................... 98
Certificates
Declaration of conformity...................................................................................... 99
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 99
Keyword index.................................................................................................... 101
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 7
••• 2. Checking all connections on the heating water side
for leaks
•3. Venting the boiler........................................................... 8
•4. Venting the heating system
• • 5. Draining the heating system (if required)..................... 9
•6. Filling the siphon or neutralising system (accessory)
with water........................................................................ 9
•7. Checking power supply connection
• • 8. Setting the time and date (if required).......................... 10
•9. Changing the language at the control unit................... 11
••• 10. Function sequence and possible faults....................... 11
• • 11. Removing the front panel.............................................. 13
• • 12. Opening the boiler door................................................. 14
• • 13. Cleaning the heating surfaces....................................... 14
• • 14. Closing the boiler door.................................................. 17
•15. Cleaning the burner........................................................ 18
•16. Replacing the nozzle and checking or adjusting the
ignition electrodes.......................................................... 19
•17. Burner installation.......................................................... 20
• • 18. Cleaning and replacing the oil pump filter, if
required .......................................................................... 20
• • 19. Checking gaskets and thermal insulation
components.................................................................... 21
••• 20. Checking electrical connections for tightness
• • 21. Checking the condensate drain and cleaning the
siphon (if installed)......................................................... 23
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 22. Checking the neutralising system (accessories)........ 23
• • 23. Checking the active charcoal filter (accessories)....... 23
••• 24. Checking the diaphragm expansion vessel and
system pressure
• • 25. Adjusting the standard burner settings....................... 23
• • 26. Adjusting the oil pressure and checking the vacuum 25
• • 27. Adjusting the air volume (static burner pressure)...... 26
• • 28. Fitting the front panel..................................................... 27
••• 29. Checking the function of safety valves
•30. Matching the control unit to the heating system ........ 27
•31. Adjusting the heating curves........................................ 30
•32. Linking the control unit to the LON.............................. 33
•33. Instructing the system user........................................... 35
•34. Scanning and resetting the "Service" display............. 36
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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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 16.8 °dH (3.0 mol/m3), 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 pre-charge pressure of the
diaphragm expansion vessel.
2. Remove front insulation shell A.
3. Open air vent valve B.
4. Fill the heating system at the fill
valve C in the heating return. (Mini-
mum system pressure 0.8 bar.)
5. Close air vent valve B when no
more air is being expelled.
6. Close boiler fill valve C.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Venting the boiler
1. Close the shut-off valves on the heat-
ing water side.
2. Remove front insulation shell A (if
already fitted).
3. Connect the drain hose on air vent
valve B with a drain.
4. Open valves B and C and vent
using mains pressure until no more
air noise is audible.
5. Close valves B and C and open
the heating water shut-off valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Draining the heating system (if required)
ADrain valve
Filling the siphon or neutralising system (accessory) with water
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Pull the supply hose A (siphon or neu-
tralising system) from the boiler conden-
sate drain B and fill with a little water.
Setting the time and date (if required)
Note
■ During commissioning, or after a pro-
longed time out of use, it may be nec-
essary to reset the time and date, if the
time flashes in the display.
■ When the unit is first taken into opera-
tion the display is in German (default
language setting):
Time (see step 1)
Uhrzeit
Date (see step 2)
Datum
Sa
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Changing the language at the control unit
Note
When the unit is first taken into operation
the display is in German (default lan-
guage setting):
Select heating circuit (see step 1.)
Heizkreis wählen
1
z
Outside temperature (see step 3.)
Außentemperatur
i°C
13
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
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
issues heat
demand
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 connectors
Fault
E6
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Yes
Fan starts after no
more than
10 min.
Green LED on
ignition trans-
former flashes.
No Fault Check the oil pre-
heater, fan, cables
and plug-in con-
nectors
(the oil preheater
has not switched
through; the tem-
perature is not ach-
ieved)
F9
Yes
The air pressure
switch responds
No after approx. 51 s Check the air pres-
sure switch, cables
and plug-in con-
nectors
Fault
F5
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 sol-
enoid valves
F4
Yes
Flame signal
present
Symbol A
No Fault Check ignition
electrodes, elec-
trode gaps and
connecting lines
F4
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Yes
Burner in opera-
tion.
The green LED on
the ignition trans-
former is perma-
nently on (a flame
is recognised).
For further details regarding faults, see
page 61.
Removing the front panel
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Opening the boiler door
1. Remove cables running to the fan
A from their retainers.
2. Remove screws and open the boiler
door.
Cleaning the heating surfaces
!Please note
To prevent damage to the heat exchanger,
only clean with the cleaning equipment available as accessory
Danger
Cleaning work may lead to eye injuries.
Wear protective goggles.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Clean the biferral heating surface
(front area) with brush A.
2. Clean the biferral heating surface and
the stainless steel heat exchanger
with a vacuum cleaner. Angled noz-
zle B is available as an accessory.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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3. Pull condensate hose E from the
boiler.
4. Push on-site hose D on the connec-
tor and route to a suitable vessel
C.
5. Flush stainless steel heat exchanger
with water F.
6. Check the condensate drain and
hose E for contamination.
Clean with a bottle brush, if required.
Never damage the hose with the
brush.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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7. Reconnect condensate hose E.8. Insert combustion chamber to the
end-stop.
Closing the boiler door
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the burner
1. Undo screws, remove the lid with
mixing facility B and secure in the
maintenance position.
Note
If the mixing facility B cannot be
pulled out, open the boiler door and
push the mixing facility B by apply-
ing light pressure against the pres-
sure disc.
2. Pull the cables from the oil preheater
A and the ignition electrodes E.
3. Undo Allen screw C and remove
rifling facility D.
4. Clean the restrictor, dosing ring and
ignition electrodes.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Replacing the nozzle and checking or adjusting the ignition elec-
trodes
2.5 mm
a
1. Undo nozzle F whilst holding the oil
preheater. Prevent the formation of
bubbles.
2. Insert a new LE nozzle F (whilst
holding the oil preheater).
Select the nozzle in accordance with
the details on page 24.
3. Insert rifling facility D as far as pos-
sible. Align ignition electrodes E in
accordance with the drilled holes
towards the cable entries. Install the
oil burner nozzle centrally into the
restrictor.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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4. Secure Allen screw C of the rifling
facility. Check nozzle gap "a". !Please note
An incorrectly adjusted nozzle
gap "a" can result in irregular
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
Burner installation
Tighten screws/bolts across and click
cables back into place.
Cleaning and replacing the oil pump filter, if required
Danfoss oil pump, type BFP 52
A
B
C
AFilter plug
BO-ring (replace)
CFilter (replace)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 774 GB