Viessmann VITOLADENS 300-W Operating instructions

Service instructions
for contractors
VIESMANN
Vitoladens 300-W
Type VP3B, 12.9/19.3 kW, 16.1/23.5 kW
Wall mounted oil fired condensing boiler
for the combustion of low sulphur fuel oil DIN 51603-EL-1
with integral boiler control unit
For applicability, see the last page
VITOLADENS 300-W
5692 799 GB 2/2009 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
5692 799 GB

3
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.)
5692 799 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Codes
Code 1.................................................................................................................. 36
Code 2.................................................................................................................. 39
Resetting codes to their delivered condition......................................................... 55
Service scans
Service level overview ......................................................................................... 56
Temperatures, boiler coding card and brief scans .............................................. 56
Checking outputs (relay test)................................................................................ 58
Scanning operating conditions and sensors ........................................................ 59
Troubleshooting
Fault display......................................................................................................... 61
Fault codes .......................................................................................................... 63
Repairs................................................................................................................. 69
Function description
Control unit........................................................................................................... 78
Extensions for external connections (accessories).............................................. 80
Control functions.................................................................................................. 82
Remote control DIP switches............................................................................... 88
Designs
Connection and wiring diagram – internal connections ....................................... 90
Connection and wiring diagram – external connections....................................... 91
Parts lists............................................................................................................ 93
Safety components
Replacing safety components.............................................................................. 99
Commissioning/service reports........................................................................ 100
Specification....................................................................................................... 101
Certificates
Declaration of conformity...................................................................................... 102
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 102
Index
Index
5692 799 GB

5
Keyword index.................................................................................................... 104
Index
Index (cont.)
5692 799 GB

6
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 8
•2. Venting the boiler........................................................... 9
•3. Venting the heating system........................................... 9
•4. Filling the siphon with water......................................... 10
•5. Checking power supply connection
• • 6. Setting the time and date (if required).......................... 11
•7. Changing the language at the control unit................... 12
••• 8. Function sequence and possible faults....................... 12
• • 9. Adjusting the standard burner settings....................... 14
• • 10. Adjusting the oil pressure and checking the vacuum 16
• • 11. Adjusting the air volume (static burner pressure)...... 17
•12. Cleaning the burner........................................................ 18
•13. Replacing the nozzle and checking or adjusting the
ignition electrodes.......................................................... 19
• • 14. Cleaning and replacing the oil pump filter, if
required .......................................................................... 21
• • 15. Checking the heat exchanger for contamination........ 22
• • 16. Cleaning the heat exchanger......................................... 23
• • 17. Checking the condensate drain and cleaning the
siphon.............................................................................. 24
• • 18. Checking the neutralising system (accessories)........ 24
• • 19. Checking the active charcoal filter (accessories)....... 25
••• 20. Checking the diaphragm expansion vessel and
system pressure
••• 21. Checking all connections on the heating water side
for leaks
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 799 GB

7
Commissioning steps
Inspection steps
Maintenance steps Page
••• 22. Checking the burner (recording values on page 100
of the commissioning/service report)
••• 23. Checking the function of safety valves
••• 24. Checking electrical connections for tightness
•25. Matching the control unit to the heating system ........ 25
•26. Adjusting the heating curves (only for weather-
compensated control units)........................................... 30
•27. Linking the control unit to the LON.............................. 32
•28. Instructing the system user........................................... 34
•29. Scanning and resetting the "Service" display............. 35
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 799 GB

8
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/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.
A
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
2. Fill the heating system via boiler fill &
drain valve A in the heating return
(at the connection set or on site).
(Minimum system pressure
0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its central
position, and the system will be com-
pletely filled.
3. If the control unit had already been
switched ON before filling began:
Switch ON the control unit and acti-
vate the fill program via coding
address "2F:2".
Note
To call up code 1 and for setting the
coding address, see page 36.
4. Close boiler fill & drain valve A.
5. Close the shut-off valves on the heat-
ing water side.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 799 GB

9
Venting the boiler
A
B
1. Close the shut-off valves on the heat-
ing water side.
2. Connect the drain hose between top
valve B and a drain outlet.
3. Open valves A and B and vent
using mains pressure until no more
air noise is audible.
4. Close valves A and B and open
the heating water shut-off valves.
Venting the heating system
1. Start the control unit.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

10
2. Activate the venting program via cod-
ing "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 36.
For function and sequence of the
venting program, see page 83.
When the venting program is ena-
bled, the display shows "Entlüftung"
(Venting).
3. Check the system pressure.
Filling the siphon with water
A
1. Remove the retaining clip and siphon
A.
2. Fill the siphon with water.
3. Fit siphon A and secure with the
retaining clip.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

11
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.)
5692 799 GB

12
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.)
5692 799 GB

13
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.)
5692 799 GB

14
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 63.
Adjusting the standard burner settings
Standard burner settings
Note
Check that the service instructions are valid for the relevant burner (see applicability
on the last page and the serial no. on the boiler type plate).
A
AFlue gas test port
Rated output kW 12.9/19.3 16.1/23.5
Burner stage Stage 1 Stage 2 Stage 1 Stage 2
Rated output kW 12.9 19.3 16.1 23.5
Oil burner nozzle Type 80°H LE V 80°H LE V
Make: Danfoss Gph 0.40 0.50
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

15
Rated output kW 12.9/19.3 16.1/23.5
Oil pressure
approx.*1 bar 8.0-10.5 14.0-17.5 9.0-13.5 16.0-18.5
Max. permissible
vacuum
in the oil feed line
bar 0.35 0.35 0.35 0.35
Oil throughput kg/h 1.05 1.58 1.53 1.92
approx. l/h 1.24 1.86 1.80 2.26
Static burner pres-
sure approx.
mbar 8.0-10.5 15.5-19.5 11.0-15.5 17.5-21.0
CO2 content approx.
■ Test value w/o cap % 12.2-13.4 12.2-13.2
■ Test value with cap % 12.7-13.9 12.7-13.7
Nozzle gap "a" mm 3.0 +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.
Installation position, oil preheater
Position the oil preheater in the recess of the mixer facility in accordance with the
diagram.
*1 Due to nozzle tolerances and varying oil characteristics, the oil pressure may vary
from the values shown.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

16
Adjusting the oil pressure and checking the vacuum
D
A
C
B
Oil pump; make: Danfoss, type BFP 52
1. Insert the pressure gauge (range
0 - 25 bar) into test port "P" A and
the vacuum gauge (range 0 - 1 bar)
into test port "V" B.
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

17
3. Press K and d simultaneously 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 con-
tamination and check the pipe route.
5. If required, adjust the oil pressure for
stage 1 at pressure adjusting screw
C of the oil pump (for standard val-
ues, 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
D of the oil pump.
9. Check the actual emission values
after adjusting the oil pressure.
10. After testing, press d.
Adjusting the air volume (static burner pressure)
A
1. Start the boiler.
2. Remove plug A from the test port.
3. Connect the U-shaped pressure
gauge to test port A.
4. Press K and F simultaneously
until "Speed stage 1" and a value
between 1 and 255 are displayed.
5. Change the value with a/b until
the static burner pressure displayed
by the U-shaped pressure gauge and
the CO2 flue gas content 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

18
9. Seal test connector A again with the
previously removed plug.
Note
Do not seal the connector next to test
connector A.
Cleaning the burner
A
C
D
B
1. Undo nuts, remove the lid with mixer
equipment A and secure in the
maintenance position.
2. Pull the leads off ignition electrodes
B.
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.)
5692 799 GB

19
Replacing the nozzle and checking or adjusting the ignition elec-
trodes
2.5 mm
a
C
D
E
B
1. Undo nozzle E whilst holding the oil
preheater. Prevent the formation of
bubbles.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB

20
V
V
2. Insert a new LE nozzle E (whilst
holding the oil preheater).
Select the nozzle in accordance with
the details on page 14.
!Please note
Only use nozzles marked
"V" (on the hexagon) (see
Fig.).
3. Insert rifling facility D as far as pos-
sible. Align ignition electrodes B in
accordance with the drilled holes
towards the cable entries. Install the
oil burner nozzle centrally into the
restrictor.
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
Nozzle gap "a" (see page 19) mm 3.0 +0.2/-0.3 1.5 +0.2/-0.3
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 799 GB