Viessmann Vitolig 300 Operating instructions

VIESMANN
Service instructions
for contractors
Vitolig 300
Type VL3A
Pellet boiler
VITOLIG 300
5692 618 GB 8/2005 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
engineer.
&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 lead to
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 618 GB

Working on the system
&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 mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
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 or conversions
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 618 GB

Commissioning and adjustment
Calling up the service level ......................................................................... 5
Changing parameters and calling up operating information.......................... 6
Commissioning........................................................................................... 8
Actuator test ............................................................................................... 8
Operating and service documents ............................................................... 9
Instructing the system user ......................................................................... 9
Inspection and maintenance
1. Shutting down the heating system ........................................................... 10
2. Combustion chamber .............................................................................. 10
3. Burner .................................................................................................... 12
4. Induced draught fan and secondary heating surface ............................... 13
5. Ash chamber, secondary heating surface ................................................ 14
6. Ash removal............................................................................................ 15
7. Pellet hopper .......................................................................................... 16
8. Boiler control .......................................................................................... 17
9. Water container of the back burning protection ........................................ 18
10. Changeover unit of the automatic charging system ................................ 19
11. Checking the diaphragm expansion vessel and system pressure ........... 19
12. Checking the function of the thermally activated safety valve ................. 20
13. Checking the mixer for obstructions and leaks ....................................... 20
14. Heating test .......................................................................................... 21
15. Checking the draught ............................................................................ 21
Troubleshooting
Fault messages .......................................................................................... 22
Repairs ...................................................................................................... 26
Connection and wiring diagrams ............................................................. 27
Parts lists
Parts list ..................................................................................................... 33
Commissioning/service reports ............................................................... 44
Specification............................................................................................. 45
Certificates
Declaration of conformity ............................................................................ 46
Keyword index .......................................................................................... 47
Index
4
Index
5692 618 GB

See also the operating instruc-
tions.
Calling up the service level
At the service level of the control unit, system parameters can be changed and
commissioning steps or actuator tests can be carried out.
For information regarding the menu controls, see the operating instructions.
1. Press "Menu". The display shows
"user level" and "service level".
2. With "V" or "v" select menu
option "service level" and confirm
with "select".
3. Hold down key "5 s" longer than
5 s. The display shows the sub-
options "Parameter", "Commis-
sioning" and "Actuator test".
4. With "V" or "v" select menu
option and confirm with "select".
5. Exit the menu with "back".
This will also occur automatically
after 45 s.
Index (cont.)
5
Commissioning and adjustment
5692 618 GB

1. In menu option "Parameter" high-
light the required sub-option with
"V" or "v" and confirm with
"select".
2. Change the required parameter
with "+" or "–".
3. Save the selected value with "yes".
The display briefly shows "Para-
meter value is being saved".
Under menu option "Parameter" you can adjust the following
parameters or call up information:
Number of burner starts
The present number of burner starts is
shown
Amount of fuel through the supply auger
The amount of fuel captured by the
combustion controller is displayed in
kg/h.
Hysteresis burner ON
Switching hysteresis for burner con-
trol.
Delivered condition: 5 K
Setting range: 0 to 20 K
Maximum value of the set temperature
Maximum set boiler water tempera-
ture in heating mode
Delivered condition: 75 °C
Setting range: 60 to 75 °C
Set temperature ext. heat demand
Set boiler water temperature in case
of external heat demand
Delivered condition: 75 °C
Setting range: 35 to 75 °C
Pellet supply
A pellet supply system must be
adjusted subject to the type of pellet
extraction from the storage room.
Delivered condition: without supply
system
Optional changes:
Changing parameters and calling up operating information
6
Commissioning and adjustment
5692 618 GB

&Suction turbine with 3 wands
&Suction turbine with 2 wands
&Suction turbine agitator
Runtime of the suction turbine
Set the runtime of the suction turbine
subject to the length of the supply line
and the head.
Delivered condition: 50 s
Setting range: 20 to 70 s
Required runtime of the suction turbine
Length of the
supply line in m
Suction head in m
0–2.8 2.8 –4.5 >4.5
5–10 40 s 50 s 60 s
10 –15 50 s 60 s —
15 –20 60 s — —
20 –25 70 s — —
Number of grate shakings
To remove the ash, the grate in the
burner pot is shaken by a motor in
specified intervals. The number of
shakes per event can be adjusted.
Rated output kW 9.9 and 15.0 21.0 and 25.9
Opera-
tion
Burnout Opera-
tion
Burnout
Delivered condition 20 40 20 30
Setting range 10 –30 15 –60 10 –30 15 –60
Ventilation air/extract air damper
The runtime of a connected ventila-
tion air or extract air damper can be
adjusted at the control unit.
Delivered condition: Control OFF, run-
time in seconds 300
Setting range: 0 to 600 s
Note
The selected runtime should be twice
as long as the actual damper runtime.
Changing parameters and calling up operating . . . (cont.)
7
Commissioning and adjustment
5692 618 GB

In menu option "Commissioning" high-
light the required sub-option with "V"
or "v" and confirm with "select".
The following functions can be adjusted under menu option
"Commissioning":
Supply auger
The supply auger is started for 6 min.
Supply
The supply and every wand is started
with a purging program subject to the
selected supply system.
Actuator test
In menu option "Actuator test" high-
light the required sub-option with "V"
or "v" and confirm with "select".
Note
The functions are respectively started
for 1 min. The control unit carries out
a self-test following the termination of
the actuator test.
The following functions can be con-
trolled:
&Induced draught fan
&Supply auger
&Grate shaking
&Ignition element
&Ash removal
&Heating surface cleaner
&Suction turbine
&Wand changeover
&Ventilation/extract air damper
Commissioning
8
Commissioning and adjustment
5692 618 GB

File all parts lists, operating and ser-
vice instructions in the folder and
hand this over to the system user.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the opera-
tion of the system.
Operating and service documents
9
Commissioning and adjustment
5692 618 GB

!Please note
Hot gases can escape from the
combustion chamber.
Only open the combustion
chamber door when the system
ON/OFF switch has been
switched off.
Operating instructions
2. Combustion chamber
Note
Clean the boiler with a vacuum clea-
ner and the cleaning implements sup-
plied.
1. Shutting down the heating system
10
Inspection and maintenance
5692 618 GB

1. Check the combustion chamber
door for leaks. If in doubt, test with
a paper strip. A paper strip (approx.
20 mm wide) that has been jammed
into the door gap must not be able
to be pulled out.
2. If required, adjust the door hinges.
3. Lift reversing plate Aat the back
and remove at a slant towards the
front.
4. Clean reversing plate A.
5. Remove flying ash from combus-
tion chamber temperature sensor
B(behind the reversing plate).
6. Refit reversing plate A.
7. Clean drop chute Cwith cleaning
tool D.
8. Check the condition of the combus-
tion chamber cover panels.
2. Combustion chamber (cont.)
11
Inspection and maintenance
5692 618 GB

1. Remove cone Awith cleaning
tool B, then remove deposits with
a spatula from cone A.
2. Remove primary air spigot Cand
carefully clean the holes. The holes
must be completely free from
obstruction.
3. Lift grate plate Dwith cleaning
tool Band remove. Remove ash
residues from the grate plate and
from the centre holes.
4. Clean burner pot Eand grate
inside the burner pot with a spatula.
Vacuum burner pot Eand primary
air pipe in the centre of the burner
pot.
5. Assemble in reverse order. Ensure
that the shaker handle locks into
the recess of grate plate Dand
that web Fon the burner pot locks
into the recess on cone A.
3. Burner
12
Inspection and maintenance
5692 618 GB

1. Flip up control unit A.
2. Release four wing nuts and remove
fan unit B. Check the gasket for
tight fit and condition.
3. Clean impeller Cwith spatula.
Vacuum fly ash from the impeller,
lid and fan box.
4. Lift the fan box Dat the front and
lift out.
5. Cleaning the flue pipe.
6. Vacuum the upper area of second-
ary heating surface E.
7. Assemble in reverse order.
Note
Tighten the wing nuts diagonally.
4. Induced draught fan and secondary heating surface
13
Inspection and maintenance
5692 618 GB

8. Test the function of the heating sur-
face cleaner by pressing the reset
button (starting the system).
5. Ash chamber, secondary heating surface
1. Vacuum the ash chamber.
2. Remove ash deflector panel A.
3. Turn locking clip Bto the left and
remove clean-out cover C.
4. Induced draught fan and secondary heating . . . (cont.)
14
Inspection and maintenance
5692 618 GB

4. Rake ash out.
5. Vacuum the remaining fly ash.
6. Install clean-out cover Cand lock
into place.
7. Insert ash deflector panel A.
6. Ash removal
1. Open l.h. door.
2. Pull out handle Aas far as possi-
ble. The side opening is closed.
3. Release toggle B, push container
slightly to the left and remove.
4. Empty the ash container.
5. Check gaskets between ash
container and boiler and the gasket
on the lid of the ash container for
tight fit and condition.
6. Refit the ash container in reverse
order.
7. Check the function of the automatic
ash removal. For this, press the
reset button and the door contact
switch in the combustion chamber
door.
5. Ash chamber, secondary heating surface (cont.)
15
Inspection and maintenance
5692 618 GB

1. Open casing door A.
2. Position a suitable container B
below the opening.
3. Undo two knurled nuts of clean-out
cover Cand carefully remove the
cover. Pellets may drop out, sub-
ject to the current fill level.
4. Remove pellet residues and dust
from the hopper.
Note
Pellet dust is purely organic and
can be disposed of with biowaste.
5. Remove dust from the supply unit
and from flap D.
6. Check flap Dfor ease of opera-
tion. It must lie flush over the entire
sealing face.
7. Refit clean-out cover Cand close
door A.
7. Pellet hopper
16
Inspection and maintenance
5692 618 GB

1. Remove lid Aand flip up control
unit cover B.
2. Undo screws and remove lid C.
3. Undo screw and flip up control unit
top D.
4. If required, clean the PCB with
compressed air or a vacuum clea-
ner.
5. Check the electrical plug-in con-
nections for tight fit.
6. Check the routing of electrical
cables/leads. These must neither
touch hot components (e.g. fan
box) nor be squashed in.
7. Close control unit again.
8. Boiler control
17
Inspection and maintenance
5692 618 GB

1. Check the water level on level
indicator Aand top up, if required.
2. Slightly lift the front panel of supply
unit Band remove.
3. Remove plug Cand fill with water.
4. Refit plug Cand fit front panel B.
9. Water container of the back burning protection
18
Inspection and maintenance
5692 618 GB

1. Check changeover unit Afor
leaks and ease of operation.
2. With the wand changeover, control
all wands and supply pellets by
way of testing.
Operating instructions
11. Checking the diaphragm expansion vessel and system pres-
sure
Observe the diaphragm expansion vessel manufacturer’s instructions.
Carry out this test on a cold system.
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure,
until the pressure gauge indi-
cates "0".
2. If the inlet pressure of the dia-
phragm expansion vessel is lower
than the static system pressure,
top up with sufficient nitrogen to
raise the inlet pressure above (0.1
to 0.2 bar) the static system pres-
sure.
The static pressure corresponds to
the static head.
10. Changeover unit of the automatic charging system
19
Inspection and maintenance
5692 618 GB

3. Top up the heating system with
water and vent, until the filling pres-
sure of a cool system is higher (0.1
to 0.2 bar) than the inlet pressure
of the diaphragm expansion ves-
sel.
12. Checking the function of the thermally activated safety valve
Only for the Vitolig 300 with 21.0 and
25.9 kW.
1. Activate the valve of the thermally
activated safety valve: Push red
cap Aagainst the valve.
Water must flow from the valve.
2. In case of a low throughput, check
the heat exchanger for scaling and
sludge deposits.
Clean, if required.
13. Checking the mixer for obstructions and leaks
1. Check the mixer for ease of opera-
tion.
2. Check the mixer for leaks.
Replace the O-rings in case of
leaks.
11. Checking the diaphragm expansion vessel and . . . (cont.)
20
Inspection and maintenance
5692 618 GB