Viessmann VITOLADENS 300-W Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitoladens 300-W
Type VP3C, 12.7 kW to 23.3 kW
Wall mounted oil condensing boiler
For applicability, see the last page
VITOLADENS 300-W
5686 295 GB 8/2016 Please keep safe.

2
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 intended for author-
ised contractors.
■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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
When water escapes from the appliance there is
a risk of electrocution.
Switch off the heating system by means of an
external isolator (for example fuse box, domestic
power distribution).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Safety instructions
Safety instructions
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Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
2. Installation sequence Preparing for boiler installation .............................................................. 8
Mounting the boiler and making connections ........................................ 9
Flue gas connection ............................................................................... 10
Condensate connection ......................................................................... 11
Installing the oil supply as a single line system ..................................... 12
Opening the control unit enclosure ........................................................ 12
Electrical connections ............................................................................ 14
■Power supply fÖ ................................................................................. 14
■Connecting accessories ..................................................................... 15
■Routing connecting cables ................................................................. 16
Closing the control unit enclosure and inserting the programming unit . 17
Connecting the fire safety switch (for a only) ..................................... 17
Fitting the front panel ............................................................................. 19
3. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 20
4. Code 1 General .................................................................................................. 43
■Coding ................................................................................................ 43
Boiler ...................................................................................................... 45
■Coding ................................................................................................ 45
DHW ...................................................................................................... 45
■Coding ................................................................................................ 45
Solar ...................................................................................................... 46
■Coding ................................................................................................ 46
Heating circuit 1, heating circuit 2, heating circuit 3 ............................... 47
■Coding ................................................................................................ 47
5. Code 2 General .................................................................................................. 51
■Coding ................................................................................................ 51
Boiler ...................................................................................................... 56
■Coding ................................................................................................ 56
DHW ...................................................................................................... 57
■Coding ................................................................................................ 57
Solar ...................................................................................................... 58
■Coding ................................................................................................ 58
Heating circuit 1, heating circuit 2, heating circuit 3 ............................... 60
■Coding ................................................................................................ 60
6. Diagnosis and service
scans
Calling up the service level .................................................................... 66
■Exiting the service level ...................................................................... 66
Diagnosis ............................................................................................... 66
■Scanning operating data ..................................................................... 66
■Brief scan ............................................................................................ 67
Testing outputs (relay test) ..................................................................... 68
7. Troubleshooting Fault display ........................................................................................... 69
■Weather-compensated control unit ..................................................... 69
Fault codes ............................................................................................ 69
Index
Index
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Maintenance .......................................................................................... 74
■Checking the outside temperature sensor (weather-compensated
control unit) ......................................................................................... 74
■Checking the boiler water temperature sensor, cylinder temperature
sensor or flow temperature sensor for the low loss header ................ 75
■Checking flue gas temperature sensor ............................................... 76
■Checking the temperature limiter ........................................................ 77
■Checking the fuse ............................................................................... 78
■Mixer extension kit .............................................................................. 78
■Checking the Vitotronic 200-H (accessories) ...................................... 79
8. Function description Control unit ............................................................................................ 80
■Heating mode ..................................................................................... 80
■DHW heating ...................................................................................... 80
■Boosting DHW heating ....................................................................... 80
■Internal H3 extension .......................................................................... 81
External extensions (accessories) ......................................................... 82
■AM1 extension .................................................................................... 82
■EA1 extension .................................................................................... 83
Control functions .................................................................................... 84
■External operating program changeover ............................................ 84
■External blocking ................................................................................ 85
■External demand ................................................................................ 85
■Venting program ................................................................................. 86
■Fill program ......................................................................................... 86
■Screed drying ..................................................................................... 86
■Raising the reduced room temperature .............................................. 88
■Reducing the heat-up time ................................................................. 89
Assigning heating circuits to the remote control .................................... 90
9. Designs Connection and wiring diagram – internal connections ......................... 91
Connection and wiring diagram – external connections ........................ 92
10. Parts lists Ordering parts ........................................................................................ 94
Overview of assemblies ......................................................................... 95
Casing assembly ................................................................................... 96
Heat cell assembly ................................................................................. 98
Burner assembly ....................................................................................100
■Oil pump ............................................................................................. 102
■Suntec oil pump ..................................................................................104
■Danfoss oil pump ................................................................................106
Hydraulic assembly ................................................................................108
Control unit assembly ............................................................................ 110
Miscellaneous assembly ........................................................................ 112
11. Commissioning/service
reports
................................................................................................................ 114
12. Specification ................................................................................................................ 115
13. Certificates Declaration of conformity ....................................................................... 117
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 118
14. Keyword index ................................................................................................................ 119
Index
Index (cont.)
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is intended solely for installation and
operation in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for heating up heating water
that is of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Information
Disposal of packaging
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Information

7
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Information
Intended use (cont.)
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Information

8
!Please note
Avoid damaging the appliance.
Connect all pipework free of load and torque
stress.
For on-site preparation of the water and electri-
cal connections, see the installation instructions
for the pre-plumbing jig or mounting frame.
480
min. 350
850
380
1925
BA C EFD
G
K
H
Fig. 1
AHeating flow Rp ¾
BExpansion vessel connection G ¾
CCylinder flow G ¾
DCylinder return G ¾
EHeating return Rp ¾
FFilling/draining
GWiring area
HDimension for installation with DHW cylinder below
the boiler
KCondensate drain
1. Prepare the water connections. Thoroughly flush
the heating system.
2. Prepare the oil connections (oil filter):
■Single line filter (magnum filter bowl with large fil-
ter element, filter grade max. 40 µm) with auto-
matic fuel oil air vent valve (see page 12).
■Fit the filter as near as possible to the lower edge
of the boiler (on l.h. or r.h. side) to leave the flexi-
ble oil lines inside the boiler long enough to
remove the burner.
3. Prepare the electrical connections.
■Power cable: NYM-J 3 x 1.5 mm2, max. fuse rat-
ing 16 A, 230 V/50 Hz
■Accessory cables: NYM with required number of
cores for external connections
■All cables in area "G" should protrude 1200 mm
from the wall
Installation sequence
Preparing for boiler installation
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Installation

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2x
1.
2.
4.
3.
Fig. 2
Installation sequence
Mounting the boiler and making connections
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Installation

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A C D E FB
1.
2.
5x
Fig. 3
AHeating flow
BExpansion vessel connection
CCylinder flow
DCylinder return
EHeating return
FFilling/draining
Flue gas connection
Note
Only use the "System certificate" and "Skoberne
GmbH flue system" labels in conjunction with the
Viessmann flue system made by Skoberne.
The labels are provided with the technical documenta-
tion.
Fig. 4
Installation sequence
Mounting the boiler and making connections (cont.)
5686 295 GB
Installation

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Note
Ensure the boiler is horizontally and vertically aligned
when mounting on the wall.
Connect the balanced flue system to the boiler flue
connection.
Note
If a balanced flue system with
7
60/100 mm is to be
connected, a balanced flue adaptor (accessories) is
required.
Flue system installation instructions
Do not carry out commissioning until the following
conditions are met:
■Free passage through the flue gas pipes.
■Flue system with positive pressure is gas-tight.
■Apertures for ensuring sufficient combustion air sup-
ply are open and cannot be closed off.
■Applicable regulations on installing and commission-
ing flue systems have been followed.
Danger
Leaking or blocked flue systems or an insuffi-
cient supply of combustion air cause life threat-
ening poisoning due to carbon monoxide in the
flue gas.
Ensure the flue system functions correctly. Aper-
tures for combustion air supply must not be able
to be closed off.
Condensate connection
A
B C
Fig. 5
AInlet from the boiler
BNeutralising system or active charcoal filter
CDrain to the public sewage system
Connect the condensate pipe to the public sewage
system by the shortest route, with a constant fall and a
pipe vent. Install a neutralising system if required.
Note
DWA-A 251 permits boiler use without a neutralising
system when operating with DIN 51605-EL-1 low sul-
phur fuel oil (sulphur content ≤ 50 mg/kg).
If no neutralising system is connected, use the active
charcoal filter (accessories).
Installation sequence
Flue gas connection (cont.)
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Installation

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Ø
A
B
H
Fig. 6
AFuel oil filter with automatic air vent valve
BFoot valve
Important: Install a single line fuel oil filter R ⅜ (filter
grade max. 40 µm) and a fuel oil air vent valve in the
oil supply.
Recommendation:
■Automatic fuel oil air vent valve with filter: FloCo-
Optimum-K (filter grade 5 µm).
■For replacement during maintenance work: Micro-
tec MC-18 oil filter element (filter grade 5 µm).
See Vitoset pricelist.
For tanks sited below the oil burner pump:
If the suction head or the max. pipe length is greater
than specified in the following table, install an oil feed
pump with intermediate tank in the immediate proxim-
ity of the boiler.
Sizing the oil line
Suction
head H in m
Max. pipe length in m for suction
line internal diameter
4 mm 5 mm 6 mm
+4.0 100 100 100
+3.5 95 100 100
+3.0 89 100 100
+2.5 83 100 100
+2.0 77 100 100
+1.5 71 100 100
+1.0 64 100 100
+0.5 58 100 100
0.0 52 100 100
-0.5 46 100 100
-1.0 40 97 100
-1.5 33 81 100
-2.0 27 66 100
-2.5 21 51 100
-3.0 15 36 75
-3.5 9 21 44
-4.0 —6 12
Note
For the oil line, select the smallest diameter required
for the suction head.
Opening the control unit enclosure
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Installation sequence
Installing the oil supply as a single line system
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Installation

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2x
4x
4.
3.
5.
2.
1.
Fig. 7
Installation sequence
Opening the control unit enclosure (cont.)
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Installation

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L N
230V~
LN
230V~
5
A
2
1
156 40
145
3217654
X3
40201124 156
Fig. 8
ARadio clock connection
Information on connecting accessories
When connecting accessories observe the sep-
arate installation instructions provided with
them.
Power supply fÖ
Danger
Incorrectly executed electrical installations can
result in injuries from electrical current and in
appliance damage.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■IEC 60364-4-41
■VDE regulations
■Connection requirements specified by your
local power supply utility
■Install an isolator in the power cable to provide
omnipolar separation from the mains for all active
conductors, corresponding to overvoltage cate-
gory III (3 mm) for full isolation. This isolator must be
fitted in the permanent electrical installation, in line
with the installation requirements.
In addition, we recommend installing an AC/DC-sen-
sitive RCD (RCD class B ) for DC (fault) cur-
rents that can occur with energy efficient equipment.
■Max. fuse rating 16 A.
Danger
The absence of component earthing can lead to
serious injury from electric current if an electrical
fault occurs.
The appliance and pipework must be connected
to the equipotential bonding of the building.
aBH ■Accessories power supply at the control unit
(230 V/50 Hz). The connection is switched by
the system ON/OFF switch.
If the total system current exceeds 6 A, connect
one or more extensions directly to the mains
supply via an ON/OFF switch.
Installation sequence
Electrical connections
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Installation

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LV plug
!Outside temperature sensor
Installation:
■North or north-westerly wall, 2 to 2.5 m above
ground level; on multi storey buildings, in the
upper half of the second floor
■Not above windows, doors or vents
■Not immediately below balconies or gutters
■Never render over
■2-core cable, max. 35 m long with a cable
cross-section of 1.5 mm2
?Flow temperature sensor for low loss header
(accessories)
%Cylinder temperature sensor (supplied with DHW
cylinder connection set)
aVG KM-BUS subscriber (accessories)
■Vitotrol 200-A or 300-A remote control
■Vitocom 100
■Mixer extension kits
■Solar control module, type SM1
■Vitosolic
■AM1 extension
■EA1 extension
■Wireless base station
Connecting accessories
Power supply and KM-BUS
Power supply to all accessories via heat generator control unit
145 145 40A 40 145 145 40A 40
B C
145 40 156
A
145 145 40A 40
D
E
Fig. 9
Some accessories with direct power supply
145 145 40A 40 145 145 40A 40
B C
145 40 156
A
145 145 40A 40
D
E
Fig. 10
AHeat generator control unit
BExtension kit for heating circuit with mixer M2
CExtension kit for heating circuit with mixer M3
DAM1 extension, EA1 extension and/or solar control
module, type SM1
EON/OFF switch
If the current flowing to the connected working parts
(e.g. circulation pumps) is higher than the fuse rating
of the relevant accessory, only use the output con-
cerned to control an on-site relay.
Accessories Internal fuse protec-
tion
Extension kit for heating circuit
with mixer
2 A
AM1 extension 4 A
EA1 extension 2 A
Solar control module, type
SM1
2 A
Installation sequence
Electrical connections (cont.)
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Installation

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Routing connecting cables
!Please note
If connecting cables come into contact with hot
components they will be damaged.
When routing and securing connecting cables
on site, ensure that the maximum permissible
temperatures for these cables are not exceeded.
EA
D
B
C
F
%
Fig. 11
ALV terminals
B230 V terminals
CInternal extension
DMain PCB
ECommunication module
FCable grommet for power cable
%Plugs for connecting the cylinder temperature sen-
sor to the cable harness
Installation sequence
Electrical connections (cont.)
5686 295 GB
Installation

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1.
6.
4.
5.
2.
2x
3.
Fig. 12
Insert the programming unit (packed separately) into
the control unit support.
Note
The programming unit can also be inserted into a wall
mounting base (accessories) near the boiler.
Wall mounting base installation instructions
Connecting the fire safety switch (for a only)
Note
Remove any existing jumper.
Installation sequence
Closing the control unit enclosure and inserting the programming unit
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Installation

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3.
5.
4.
1.
2.
Fig. 13
Installation sequence
Connecting the fire safety switch (for a only) (cont.)
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Installation

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2.
3. 2x
1.
Fig. 14
Installation sequence
Fitting the front panel
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Installation

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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Removing the front panel.................................................................................................. 21
•2. Filling the heating system................................................................................................. 21
•3. Checking the power supply
•4. Changing the language (if required)................................................................................. 22
• • 5. Setting the time and date (if required).............................................................................. 23
•6. Venting the boiler............................................................................................................... 23
•7. Venting the heating system............................................................................................... 23
•8. Filling the trap with water.................................................................................................. 24
•9. Naming the heating circuits.............................................................................................. 24
••• 10. Function sequence and possible faults........................................................................... 24
• • 11. Standard values for burner adjustment........................................................................... 26
• • 12. Adjusting the oil pressure and checking the vacuum.................................................... 27
• • 13. Adjusting the air volume (static burner pressure).......................................................... 28
•14. Cleaning the burner........................................................................................................... 29
•15. Replacing the nozzle and checking or adjusting the ignition electrodes..................... 30
• • 16. Cleaning the oil pump filter and replacing it if required................................................. 31
• • 17. Checking the heat exchanger for contamination............................................................ 33
• • 18. Cleaning the heat exchanger............................................................................................ 33
• • 19. Checking the condensate drain and cleaning the trap................................................... 34
• • 20. Checking the neutralising system (accessories)............................................................ 34
• • 21. Checking the active charcoal filter (accessories)........................................................... 35
••• 22. Checking the diaphragm expansion vessel and system pressure
••• 23. Checking all connections on the heating water side for leaks
••• 24. Checking the burner (record values on page 114 of the report)
••• 25. Checking the flue system for unrestricted flow and tightness
••• 26. Checking the safety valve function
••• 27. Checking the firm seating of electrical connections
•28. Matching the control unit to the heating system ........................................................... 35
•29. Adjusting the heating curves (only for weather-compensated control units).............. 39
•30. Linking the control unit to the LON.................................................................................. 41
•31. Instructing the system user.............................................................................................. 42
•32. Scanning and resetting the "Service" display................................................................. 42
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5686 295 GB