Viessmann VITOLIGNO 300-C Quick guide

Installation and service instructions
for contractors
Viesmann
Vitoligno 300-C
Type VL3C
Pellet boiler
60 to 70 kW
For applicability, see the last page
VITOLIGNO 300-C
5777173 GB/en 9/2017 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.
Caution
Warning of a low risk of injury. If the risk is not
avoided, it may result in minor or medium 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
Safety instructions
5777173

3
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.
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.)
5777173

4
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 8
Safety instructions regarding maintenance and cleaning ...................... 8
2. Preparing for installation Boiler room requirements ...................................................................... 9
■Boiler room floor requirements ........................................................... 9
Handling ................................................................................................. 9
■Max. tilting angle during handling ....................................................... 9
■Removing components when access is ≤ 900 mm ............................. 12
Siting requirements ................................................................................ 14
■Compensating for an uneven floor ..................................................... 15
■Minimum clearances for pellet supply with pellet hopper ................... 16
■Minimum clearances for pellet supply via flexible screw conveyor ..... 17
■Alignment of the flexible screw conveyor to the pellet store ............... 17
3. Installation sequence Fitting the programming unit .................................................................. 19
Fitting the platform ................................................................................. 20
Fitting the bottom thermal insulation ...................................................... 21
Fitting the feed ....................................................................................... 22
Installing the flue gas fan ....................................................................... 23
Fitting the casing panel .......................................................................... 24
Boiler version with pellet hopper ............................................................ 25
■Installing the pellet hopper .................................................................. 25
■Installing the pellet hopper sensor ...................................................... 27
■Fitting the feed casing to the pellet hopper ......................................... 28
■Installing the vacuum module ............................................................. 30
Boiler version with flexible screw conveyor ........................................... 31
■Installing the adaptor .......................................................................... 31
■Installing the feed casing .................................................................... 32
■Fitting the flexible screw conveyor to the room discharge adaptor ..... 34
■Adjusting the length of the flexible screw conveyor ............................ 35
■Fitting the flexible screw conveyor to the drive unit ............................ 36
■Fitting the hose support ...................................................................... 37
Installing the ash box ............................................................................. 38
Connections on the flue gas side ........................................................... 38
Making the connections on the heating water side ................................ 40
■Overview of connections .................................................................... 40
■Connecting the thermally activated safety valve ................................ 40
Electrical connections ............................................................................ 41
■Routing cables .................................................................................... 41
■Electrical connection ........................................................................... 43
■Overview of electrical connections ..................................................... 44
Power supply ......................................................................................... 53
■Isolator ................................................................................................ 53
■Recommended power cable ............................................................... 53
Fitting the casing panels ........................................................................ 54
Affixing the type plate ............................................................................ 58
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 59
5. Codes Code 1 ................................................................................................... 100
■Calling up code 1 ................................................................................100
■Overview of coding level 1 ..................................................................100
■Hardware ............................................................................................ 100
■General ...............................................................................................103
■Boiler .................................................................................................. 103
■Charging ............................................................................................. 104
■Buffer (heating water buffer cylinder) ..................................................105
Index
Index
5777173

5
■Additional heat generator ................................................................... 106
■Heating ............................................................................................... 108
■DHW ................................................................................................... 111
■Solar ................................................................................................... 111
Code 2 ................................................................................................... 113
■Calling up code 2 ................................................................................ 113
■Overview of coding level 2 .................................................................. 113
■General ............................................................................................... 113
■Boiler .................................................................................................. 114
■Charging ............................................................................................. 116
■Buffer .................................................................................................. 117
■Heating ............................................................................................... 117
■DHW ................................................................................................... 119
■Controllers .......................................................................................... 119
6. Diagnosis and service
scans
Service functions ................................................................................... 120
■Calling up the service menu ............................................................... 120
■Exiting the service menu .................................................................... 120
Checking operating states, actuators and sensors ................................121
■Calling up the "Information" menu ...................................................... 121
■Calling up the "Diagnosis" menu ........................................................ 121
Checking the outputs (actuators) ...........................................................121
■The following actuators can be switched "manually" .......................... 122
■Calling up the "Actuator test" menu ....................................................122
Filling the vacuum module ..................................................................... 123
■Calls up the "Fill vacuum module" menu ............................................ 123
Running the pellet hopper until empty ................................................... 123
■Calling up the "Run pellet hopper until empty" menu ......................... 123
Checking the changeover unit ............................................................... 124
■Calling up the "Changeover unit" menu ..............................................124
■Icons and text in the menu ................................................................. 124
■Manual operation of changeover unit ................................................. 125
Loading the standard setting ................................................................. 125
■Calling up the "Standard setting" menu ..............................................125
7. Fault rectification Fault display ...........................................................................................127
■Checking and acknowledging faults ................................................... 127
■Calling up acknowledged fault messages .......................................... 127
■Calling up fault codes from the fault memory (fault history) ............... 127
■Deleting saved fault codes from the fault memory ............................. 128
Fault displays in plain text ......................................................................128
Fault codes ............................................................................................ 128
8. Maintenance Fuses ..................................................................................................... 134
Checking the fuses ................................................................................ 134
Battery ................................................................................................... 134
High limit safety cut-out ......................................................................... 134
■Triggering the function ........................................................................ 134
■Cancelling the function ....................................................................... 134
Sensors ..................................................................................................135
■Connection ......................................................................................... 135
■Checking the sensors ......................................................................... 135
Lambda probe ........................................................................................136
■Checking the Lambda probe .............................................................. 136
■Calibrating the Lambda probe ............................................................ 136
■Connection ......................................................................................... 137
Extension kit for heating circuit with mixer .............................................137
■Flow temperature sensor ....................................................................137
■Mixer motor .........................................................................................137
■Specification extension kit .................................................................. 138
Index
Index
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6
Replacing the ignition element ...............................................................138
9. Parts lists Overview of assemblies .........................................................................139
Thermal insulation assembly ................................................................. 140
Boiler overview ...................................................................................... 143
Combustion chamber assembly ............................................................ 144
Ignition and drive systems assembly ..................................................... 146
Doors assembly ..................................................................................... 148
Ash removal assembly ...........................................................................150
Cleaning assembly ................................................................................ 152
Ash box assembly ..................................................................................154
Control unit assembly ............................................................................ 156
Return temperature raising facility assembly .........................................160
Charging overview ................................................................................. 163
Flexible screw conveyor assembly ........................................................ 164
Pellet hopper assembly ......................................................................... 166
Vacuum module assembly .....................................................................168
Feed assembly ...................................................................................... 170
Miscellaneous assembly ........................................................................172
10. Function description Display and control elements .................................................................174
■Function of "START/STOP" button ..................................................... 174
■Function of appliance mains isolator .................................................. 175
Control functions ....................................................................................175
■Heating water buffer cylinder ..............................................................175
■Solar circuit control ............................................................................. 177
■Heating circuit control unit .................................................................. 177
■Cylinder temperature control .............................................................. 180
■Screed drying function ........................................................................181
Vacuum supply system .......................................................................... 182
■Supply process ................................................................................... 182
Combustion flow chart ........................................................................... 183
11. Connection and wiring dia-
gram
Position of PCBs ....................................................................................184
Overview of PCBs ..................................................................................185
ZPK 2.02 PCB ....................................................................................... 186
HKK 2.01 PCB ....................................................................................... 188
KSK 2.03 PCB ....................................................................................... 189
List of connected cables ........................................................................ 190
12. Commissioning/service
reports
................................................................................................................193
13. Specification ................................................................................................................194
14. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 196
15. Certificates Declaration of conformity ....................................................................... 197
16. Keyword index ................................................................................................................198
Index
Index (cont.)
5777173

7
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 environmental 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 surface.
Dispose of component correctly.
Dispose of component at a suitable collection point. Do not dispose of component in do-
mestic waste.
The steps in connection with commissioning, inspection and maintenance are found in the "Commissioning,
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
Information
Disposal of packaging
5777173
Information

8
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.
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.
Safety instructions regarding maintenance and cleaning
Danger
The appliance mains isolator on the boiler is
used to isolate the control unit from the power
supply. It does not turn off the mains power sup-
ply.
There are live components inside the control
unit enclosure.
Danger
Fire from apertures and hot surfaces can cause
serious injuries.
■Apertures fastened shut with screws must not
be opened during heating operation.
■Only open the boiler after it has cooled down.
■Wear personal protective equipment.
Danger
During maintenance and cleaning work, and
when manipulating the ash box, there is a risk of
fire and burns due to hot components and ash.
■Wear suitable safety gloves.
■Only dispose of the hot ash in fireproof con-
tainers with covers.
Danger
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.
Danger
Risk of crushing or entanglement by rotating or
moving parts.
Do not reach in through the maintenance cov-
ers.
Do not remove any protective covers.
Danger
There is a risk of falling due to slipping and trip-
ping on the ash box.
Do not stand on the ash box.
Note
Before restarting the heating system, all opened cov-
ers and flaps on the boiler must be closed again.
Information
Intended use
5777173
Information

9
A separate dry boiler room must be provided for the
system. No combustible materials may be stored in the
boiler room.
Boiler room requirements:
■No air contamination by halogenated hydrocarbons
(e.g. contained in sprays, paints, solvents and clean-
ing agents)
■Dry
■High humidity levels to be avoided (e.g. caused by
continuous drying of washing)
■Prevent very dusty conditions
■Max. ambient temperature 35 °C
■Prevent frost and ensure good ventilation
■Reliable and adequate supply of fresh air
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. fuel, petrol, solvents
and cleaning agents, paints, paper).
Boiler room floor requirements
The boiler must be positioned on a non-combustible,
temperature-resistant substrate.
Requirements regarding the load bearing capacity of
the boiler room floor.
See the technical guide for the boiler
Handling
Danger
Risk of injury due to the boiler tilting or falling
■Lift at the transport lug using flexible sling gear
or shackles.
■Transport with pallet truck / forklift truck.
!Please note
Severe jolts can damage the combustion cham-
ber.
Do not subject the boiler to any severe jolts dur-
ing handling and positioning.
Note
■The boiler weighs approx. 900 kg.
■At least 2 people are needed to transport the boiler
to the installation location.
■Transport the boiler to the installation location in an
upright position and, if possible, on the pallet.
Max. tilting angle during handling
To avoid material damage and injuries, the following
tilting angles must not be exceeded during transport.
Boiler side Tilting angle
With a transport
pallet
Without a transport
pallet
■Front 25° 21°
■Back 24° 25°
■Left 25° 29°
■Right 29° 29°
Preparing for installation
Boiler room requirements
5777173
Installation

10
1. 2. 4x
Fig. 1
1. Remove thermal insulation from under the boiler.
2. Undo the transport brackets.
Preparing for installation
Handling (cont.)
5777173
Installation

11
3.
Fig. 2
3. Lift boiler off the pallet using flexible sling gear
attached to the transport lug.
4.
Fig. 3
4. Lift boiler off the pallet and transport to installation
location with a pallet truck or forklift truck.
5. Remove and retain the bag containing the boiler
type plate from the combustion chamber door.
Note
The type plate is affixed to the left-hand or right-
hand casing panel at a later time.
6. Remove the cleaning set from the boiler and keep
it safe.
Preparing for installation
Handling (cont.)
5777173
Installation

12
900
900
Fig. 4
Note
The access to the installation room must be at least
800 mm wide.
If the width of the access is less than 900 mm, first
remove certain components, as described in chapter
"Removing components for access ≤ 900 mm" below.
Removing components when access is ≤ 900 mm
1.
2.
Fig. 5
1. Remove pump head. 2. Pull out plug.
Preparing for installation
Handling (cont.)
5777173
Installation

13
5.
4.
6.
7.
3.
Fig. 6
3. Disconnect plug sYS from the power supply.
Note
The cable with plug designation s:G is not needed.
4. Use a dismantling aid, e.g. two-armed puller, to
remove the motor with torque support.
Note
Motor dimensions:
■Width = 100 mm
■Depth = 84 mm (incl. flange plate)
■Shaft diameter = 20 mm
5. Lift out the feather key.
6. Remove chain tensioner.
7. Remove chain by opening the master link.
Preparing for installation
Handling (cont.)
5777173
Installation

14
8.
9.
180°
Fig. 7
8. Dismantle gearwheel.
9. Insert ash removal screw and pull out on the oppo-
site side of the boiler.
Note
After siting the boiler in its final position, refit the com-
ponents in reverse order.
Siting requirements
■The specified wall clearances are required for instal-
lation and maintenance work.
■The space above the boiler must remain free for
maintenance work.
■Required room height: Min. 2.1 m
Preparing for installation
Handling (cont.)
5777173
Installation

15
Compensating for an uneven floor
1.
2. 4x
Fig. 8
Note
Any unevenness of the boiler room floor can be com-
pensated via the 4 adjusting screws on the boiler.
Preparing for installation
Siting requirements (cont.)
5777173
Installation

16
Minimum clearances for pellet supply with pellet hopper
a
d
b
c
A
Fig. 9
Note
Keep area A behind the boiler clear for installation
and maintenance work.
Rated heating output kW 60 70 Notes
Wall clearances
a mm 500 500
b mm 450 (1215) 450 (1215) 200 sufficient if dimension c ≥ 450
c mm 100 100 450 required if dimension b ≤ 200
d mm 800 800
Note
Dimensions in brackets are measured up to the boiler
casing.
Preparing for installation
Siting requirements (cont.)
5777173
Installation

17
Minimum clearances for pellet supply via flexible screw conveyor
a
d
b
c
r
A
Fig. 10
APellet discharge or connector at the pellet silo
Rated heating output kW 60 70
Wall clearances
a mm 500 500
b mm 200 (965) 200 (965)
c mm 100 100
d mm 800 800
Note
Dimensions in brackets are measured up to the boiler
casing.
Note
Observe the minimum bending radius of the flexible
screw conveyor, see page 17.
Alignment of the flexible screw conveyor to the pellet store
The pellet supply with flexible screw conveyor can
either be connected to the room discharge with screw
conveyor supply system or to a pellet silo.
The pellet silo/room discharge adaptors as well as the
drive unit of the flexible screw conveyor on the Vito-
ligno can be fitted in different positions.
Preparing for installation
Siting requirements (cont.)
5777173
Installation

18
Further details regarding positioning:
See the technical guide for the boiler
Minimum clearances
X
Y
Fig. 11
APellet discharge or connector at the pellet silo
BHose with screw conveyor
Rated heating output kW 60 70
Minimum clearances, flexible screw conveyor
r Min. bending radius mm 1500 1500
X Minimum clearance if the screw conveyor is routed in a
straight line.
mm 1700 1700
Y Min. screw conveyor length mm 1850 1850
Preparing for installation
Siting requirements (cont.)
5777173
Installation

19
1.
Fig. 12
!Please note
An incorrectly routed display ribbon cable can
cause system damage.
■Do not kink or crush the ribbon cable.
■Route the ribbon cable (safety extra low volt-
age, SELV) at a sufficient distance from the
mains voltage.
■Pull the ribbon cable out of the control unit
enclosure as far as possible.
!Please note
Cutting or kinking the pipeline (capillary) of the
high limit safety cut-out (STB) can cause the
heating system to fail permanently.
■Observe the 5 mm minimum bending radius of
the pipeline.
■If the pipeline is kinked or damaged, replace
the high limit safety cut-out.
1. Fit the programming unit.
Note
Unhook and remove the securing straps on the
programming unit.
2. Plug the ribbon cable of the programming unit into
connector aYÖ of the KSK 2.03 PCB.
3. Secure the cover of the control unit enclosure with
screws.
Installation sequence
Fitting the programming unit
5777173
Installation

20
2.
1.
Fig. 13
1. Hook platform into place. 2. Pivot platform downwards.
Installation sequence
Fitting the platform
5777173
Installation