Viessmann VITOLIGNO 300-C Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitoligno 300-C
Type VL3C, 8 and 12 kW
Pellet boiler
For applicability, see the last page
VITOLIGNO 300-C
5684 825 GB 9/2015 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 quali-
fied 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
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'.
Note
In addition to the control circuit there may be several
power circuits.
Danger
Contact with 'live' components can result in
severe injuries. Some components on PCBs
remain 'live' even after the power supply has
been switched off.
Wait at least 4 minutes before removing equip-
ment covers, to allow the voltage to dissipate.
■Safeguard the system against reconnection.
!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.
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.
Installation room
Danger
Suffocation hazard due to carbon monoxide pro-
duced during incomplete combustion due to lack
of combustion air.
Ensure an adequate supply of fresh air. Never
cover or close vents.
Danger
Easily flammable liquids and materials can
cause deflagration and fires.
Do not store easily flammable substances in the
boiler installation room (e.g. petrol, solvents and
cleaning agents, paints, paper).
Safety instructions
Safety instructions
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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Maintenance and cleaning ..................................................................... 7
2. Preparing for installation ................................................................................................................ 8
3. Installation sequence Fitting accessories for room sealed operation ....................................... 11
Conversion for manual filling ................................................................. 14
Fitting the casing panels ........................................................................ 15
Routing cables and leads ...................................................................... 17
Electrical connection .............................................................................. 17
■Overview of electrical connections ..................................................... 18
■Inserting cables and leads into the control unit enclosure and apply-
ing strain relief .................................................................................... 18
■Connecting the outside temperature sensor ....................................... 18
■Connecting the buffer temperature sensors ....................................... 19
■Other electrical connections ............................................................... 19
■Power supply ...................................................................................... 19
Fitting the control unit cover and protective panel ................................. 20
Connections on the flue gas side ........................................................... 21
Connections on the water side .............................................................. 22
Fitting further casing panels ................................................................... 23
Fitting the pellet flap ............................................................................... 24
Affixing the type plate ............................................................................ 25
Connecting the pellet supply and return air hoses ................................ 25
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 27
5. Codes Code 1 ................................................................................................... 50
■Call up code 1 ..................................................................................... 50
■General ............................................................................................... 50
■Charging ............................................................................................. 50
■Hardware ............................................................................................ 52
■Heating ............................................................................................... 54
■Boiler .................................................................................................. 56
■Buffer .................................................................................................. 58
■Solar ................................................................................................... 59
■DHW ................................................................................................... 60
■Additional heat generator ................................................................... 60
Code 2 ................................................................................................... 61
■Calling up code 2 ................................................................................ 61
■General ............................................................................................... 62
■Charging ............................................................................................. 62
■Heating ............................................................................................... 63
■Boiler .................................................................................................. 64
■DHW ................................................................................................... 67
6. Service scans Service functions ................................................................................... 68
■Calling up the service menu ............................................................... 68
■Leaving the service menu ................................................................... 68
Scanning operating conditions and sensors .......................................... 68
Index
Index
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7. Troubleshooting Fault display ........................................................................................... 69
■Checking and acknowledging faults ................................................... 69
■Calling up acknowledged fault messages .......................................... 69
■Fault displays in plain text .................................................................. 69
■Calling up fault codes from the fault memory (fault history) ............... 69
■Deleting the fault codes from the fault memory .................................. 70
■Fault codes ......................................................................................... 70
8. Maintenance Fuses ..................................................................................................... 74
Battery ................................................................................................... 74
High limit safety cut-out ......................................................................... 74
■Triggering the function ........................................................................ 74
■Cancelling the function ....................................................................... 74
Sensors .................................................................................................. 75
■Connection ......................................................................................... 75
■Checking sensors ............................................................................... 75
Lambda probe ........................................................................................ 76
■Checking the Lambda probe .............................................................. 76
■Calibrating the Lambda probe ............................................................ 76
■Connection ......................................................................................... 76
■Lambda probe specification ................................................................ 77
Extension kit for heating circuit with mixer ............................................. 77
■Flow temperature sensor .................................................................... 77
■Mixer motor, part no. 7450 657 ........................................................... 78
9. Parts lists Overview of assemblies ......................................................................... 81
Thermal insulation assembly ................................................................. 82
Boiler assembly ..................................................................................... 84
Ignition and air dampers ........................................................................ 86
Combustion chamber ............................................................................. 88
Drive unit ................................................................................................ 90
Cleaning and reversing chamber ........................................................... 92
Cover ..................................................................................................... 94
Pellet hopper assembly ......................................................................... 96
Control unit assembly ............................................................................ 98
Return temperature raising facility assembly .........................................102
Feed assembly ...................................................................................... 104
Ash box assembly ..................................................................................106
Miscellaneous assembly ........................................................................108
10. Function description Display and operating elements ............................................................ 110
■Start-Stop pushbutton function ........................................................... 110
Control functions .................................................................................... 110
■Solar circuit control unit ...................................................................... 110
■Heating circuit control unit .................................................................. 111
■Cylinder temperature control .............................................................. 113
■Screed drying ..................................................................................... 114
Vacuum supply system .......................................................................... 115
■Supply process ................................................................................... 115
Pellet combustion sequence chart ......................................................... 116
11. Connection and wiring dia-
gram
................................................................................................................ 117
12. Commissioning/service
reports
................................................................................................................123
13. Specification ................................................................................................................124
14. Disposal Final decommissioning and disposal ..................................................... 126
Index
Index
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15. Certificates Declaration of conformity ....................................................................... 127
16. Keyword index ................................................................................................................128
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 only intended to be installed and
operated 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 the heating of 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

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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 operated for longer periods when
open) is prohibited and will result in an exclusion of lia-
bility. 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) or if other fuels than those intended for this
appliance are used.
Maintenance and cleaning
!Please note
During maintenance and cleaning work, and
when manipulating the ash box, there is a risk of
fire and burns due to hot parts and ash.
■Wear suitable safety gloves.
■Only dispose of the ash in fireproof containers
with covers.
!Please note
Pellet dust, ash and soot pose a danger to the
respiratory tract during cleaning work and when
manipulating the ash box.
Wear a dust mask to protect your respiratory
tract.
Note
Observe the country-specific regulations on the dis-
posal of materials, waste and system components.
Note
Before restarting the system, all opened covers and
flaps on the boiler must be closed again.
Information
Intended use (cont.)
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Information

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Clearance dimensions
730
(700) (100)
130
(100)
130
(700)
775
850
770
Fig. 1
■Minimum room height: 1800 mm
■Dimensions in brackets: Boiler with casing
■The specified wall clearances are required for instal-
lation and maintenance work.
Installation room requirements
Installation room requirements:
■The installation room must be dry and free from the
risk of frost.
■Avoid high humidity levels (e.g. through continuous
drying of washing).
■Ambient temperatures between 0 and 35 °C
■Ensure a supply of fresh air.
Danger
Risk of poisoning from carbon monoxide pro-
duced during incomplete combustion due to
lack of combustion air.
Ensure an adequate supply of fresh air. Never
cover or close vents.
Danger
Easily flammable liquids and materials can
cause deflagration and fires.
Do not store easily flammable substances in the
boiler installation room (e.g. petrol, solvents and
cleaning agents, paints, paper).
Floor condition
The boiler must be positioned on a non-combustible
substrate. Special foundations are not required.
Handling and siting
Handling
!Please note
Severe jolts can damage the combustion cham-
ber.
Do not subject the boiler to any severe jolts dur-
ing handling and positioning.
Preparing for installation
Preparing for installation
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Installation

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!Please note
The boiler can be damaged during transport with
a sack truck.
■Only slide the sack truck under the boiler from
the right-hand side.
■Secure the boiler to the sack truck with ties.
■Pass ties underneath the vertical hanging
rails.
Transporting the boiler
■Transport the boiler to the installation location in an
upright position and, if possible, on the pallet.
■The boiler may also be transported using a sack
truck.
■When using transport aids B (accessories), 4 peo-
ple can carry the boiler. 4 pipes for screwing into the
boiler, see page 10.
■The entire boiler can be lifted by lifting eye A (see
page 10).
If doing so, first undo the cable duct and push it to
one side.
■For handling in tight spaces, individual components
at the front and the left-hand side of the boiler can be
removed.
Siting
1. Release the ties and remove the wooden crate.
For this, undo the bottom 4 wood screws. Lift the
wooden crate from the boiler. If there is not enough
space, dismantle the wooden crate.
2. Undo 4 hexagon wood screws, lift the boiler from
the pallet and set it in place.
3. Level the boiler using the 6 adjustable feet.
■First adjust the rear right adjustable foot to
approx. medium height. This foot will not be
accessible later on.
■To adjust the rear middle foot, remove the ash
box (see page 39).
4. Check all hanging rails and cross beams with a spi-
rit level.
If necessary, realign the components vertically and
horizontally. Undo the fixing screws.
5. Remove the bag containing the boiler type plate
from the left-hand cross beam and retain. The type
plate is later affixed to the left-hand casing panel.
6. Remove the cleaning brush and handle from the
boiler and retain.
Preparing for installation
Preparing for installation (cont.)
5684 825 GB
Installation

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4x
A
B
2.
3.
Fig. 2
ALifting eye
BTransport aids (4 pipes to screw in, accessories)
Screw in transport aids B as far as they will go.
Preparing for installation
Preparing for installation (cont.)
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Installation

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Removing the air damper unit
2.
3.
4.
2x
1.
Fig. 3
1. Remove the protective panel.
2. Disconnect the plugs on the air damper motors.
3. Undo 4 nuts and remove the air damper unit.
4. Remove the spacer sleeves and sliding plate.
Leave the gaskets behind the sliding plate on the
appliance.
Installation sequence
Fitting accessories for room sealed operation
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Installation

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Fitting the ventilation air box
3.
4.
6.
2.
A
2x
1.
5.
Fig. 4
ACable entry
1. Open the tensioning toggle on the ventilation air
box and remove the cover.
2. Place the ventilation air box on the ventilation air
aperture.
3. Slide the spacer sleeve onto the threaded studs
and secure the air damper unit with 4 nuts.
Torque: 6 Nm
4. Reconnect the plugs on the air damper motors.
Push the moulded-on grommets on the cables into
apertures A in the ventilation air box side wall.
Note
Check that the air damper motors are plugged in
correctly.
Plug s-D:at the bottom (primary air damper step-
per motor)
Plug s-F:at the top (secondary air damper stepper
motor)
5. Insert the cover at the bottom and secure it with the
tensioning toggle at the top.
Installation sequence
Fitting accessories for room sealed operation (cont.)
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Installation

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6. Secure the ventilation air hose to the ventilation air
box with a hose clip.
A
B
Fig. 5
ARouting with the ventilation air connection at the
back
BRouting with the ventilation air connection at the
top
1. Route the ventilation air hose inside the boiler.
Note
■Route the ventilation air connection to either the
back or the top of the boiler, as required.
■Cut out the casing panel for the ventilation air
connector at the perforation.
■If fitting the ventilation air connection at the top of
the boiler, the ventilation air connection must be
disconnected for subsequent maintenance work.
This is required to remove the rear top panel.
2. Secure the ventilation air hose to the ventilation air
connector with a hose clip.
3. After fitting the side panel (see page 15):
Insert the ventilation air connector into the casing
panel on the inside and secure it with screws from
the outside.
7 Ventilation air connector 80 mm
On-site air supply at ventilation air connector
Max. length 15 m
Max. number/angle of pipe bends 4/90°
Installation sequence
Fitting accessories for room sealed operation (cont.)
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Installation

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If the boiler is to be filled manually, fit the pellet sensor
to the bottom of the pellet hopper.
3.
2.
4.
5.
6.
1.
sVK
A
57
Fig. 6
1. Undo retaining screw A and open the filler cover of
the pellet hopper.
Installation sequence
Conversion for manual filling
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Installation

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2. Remove the pellet sensor and close the filler cover
again.
Note
■For manual filling, do not re-attach retaining
screw A.
■The sensor aperture in the filling cover does not
need to be closed.
3. Remove the bottom cover from the pellet hopper.
Note
Retain the cover for possible reuse.
4. Fit the pellet sensor in the supplied sensor panel.
5. Fit the sensor panel with the existing gasket.
6. Run the sensor lead up through the suspension rail
to the control unit and secure with cable ties.
Note
The pellet sensor will later be connected to the con-
trol unit via slot sVK (see page 118).
Fitting the casing panels
Note
For room sealed operation with the ventilation air con-
nector at the boiler rear: Cut out the perforated aper-
ture in the back panel before fitting it.
Installation sequence
Conversion for manual filling (cont.)
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Installation

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4x
4.
3.
2.
A
A
1.
Fig. 7
AEdge protector
Note
Edge protector and self-tapping screws ST 4.8 x 9.5
are included in the delivery.
Note
The front panel and the top panels are fitted later.
Installation sequence
Fitting the casing panels (cont.)
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Installation

17
3x
2.
3.
1.
Fig. 8
!Please note
Contact with hot components causes cable
damage.
After installation, cables must not come into con-
tact with hot components.
1. Open the cover of the control unit enclosure.
2. Route external wiring through the left-hand aperture
in the casing back panel.
3. Route external wiring to the control unit enclosure
at the front. Secure cables to the left upper cross
beam with cable ties.
4. Route the internal wiring and secure with cable ties.
Note
The cables must not obstruct any later maintenance
work.
5. Depending on which side the control unit is connec-
ted on, route cables to the left-hand top or bottom
of the control unit enclosure.
Electrical connection
When connecting external switch contacts and compo-
nents to the protective low voltage of the control unit,
please observe the relevant safety requirements of
protection class II: 8 mm air and creep paths and
2 mm insulation thickness against 'live' components.
For all components provided on site, ensure safe elec-
trical separation in accordance with EN 60 335 and
IEC 65. On-site components include a PC/laptop.
Installation sequence
Routing cables and leads
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Installation

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!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.
Overview of electrical connections
Overview of PCBs and connection and wiring
diagram from page 117.
Inserting cables and leads into the control unit enclosure and applying strain relief
Cable with cast-on cable entry
2.
3.
1.
Fig. 9
Cable without cast-on cable entry
2.
1.
Fig. 10
Blank off unnecessary knockouts in the lower part of
the control unit with cable grommets (not cut out).
Connecting the outside temperature sensor
Plug !: Outside temperature sensor
1 2
1
Fig. 11
Assigned Function Additional information
1 Ai Pt1000
2 GND
Installation sequence
Electrical connection (cont.)
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Installation

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Connecting the buffer temperature sensors
Plug ): Buffer temperature sensors
1
9
23456
Fig. 12
Assigned Function Additional information
1 Buffer temperature sensor 1 (top) Pt1000
2 Buffer temperature sensor 2 Pt1000
3 Buffer temperature sensor 3 Pt1000
4 Buffer temperature sensor 4 Pt1000
5 Buffer temperature sensor 5 Pt1000
6 GND (for all 5 sensors) —
Other electrical connections
Make other electrical connections according to the
"System examples" manual and the connection and
wiring diagrams from page 117.
Power supply
Power supply fÖ see page 122.
Connect the power supply and implement all safety
measures (e.g. RCD circuit) in accordance with
IEC 60364-4-41, the connection requirements of your
local power supply utility, and VDE or national regula-
tions. Protect the power cable to the control unit with a
C 16 A max. rated MCB/fuse.
Note
Make earthing cable PE longer than the other connect-
ing cables to ensure it will not be pulled off under ten-
sion.
Power supply for DHW circulation pump
Connect DHW circulation pumps with standalone func-
tions directly to the 230 V ∼ supply.
Mains connection via the Viessmann control unit or
Viessmann control unit accessories is not permissible.
Isolator
Install an isolator in the power cable to provide omnip-
olar separation from the mains for all active conduc-
tors, corresponding to overvoltage category III (3 mm)
for full isolation. This isolator must be fitted in the per-
manent electrical installation, in line with the installa-
tion requirements.
Recommended power cable
3-core cable selected from the following options:
■H05VV-F3G 1.5 mm2
■H05RN-F3G 1.5 mm2
1. Check that the power cable to the control unit is fit-
ted with a fuse with a max. rating of C 16 A.
Installation sequence
Electrical connection (cont.)
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Installation

20
2. Connect the power cable in the junction box and
the control unit (on-site).
Danger
Incorrect core assignment can result in seri-
ous injury and damage to the appliance.
Take care not to interchange wires "L1" and
"N".
Colour coding to DIN IEC 60757:
BN Brown
BU Blue
GNYE Green/yellow
Fitting the control unit cover and protective panel
2.
1.
Fig. 13
Installation sequence
Electrical connection (cont.)
5684 825 GB
Installation