Viessmann Vitoligno 300-H Operating instructions

Installation and service instructions
for contractors
Viesmann
Vitoligno 300-H
Type VH3, 50 to 60 kW
Boiler for woodchips and pellets
VITOLIGNO 300-H
5679249 GB 10/2019 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son 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
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
Wear suitable personal protective equip-
ment when carrying out any work.
Danger
Touching live components can
result in life threatening injuries.
After switching off the ON/OFF
switch on the control unit, there are
still live components inside the con-
trol unit enclosure.
■Isolate the system from the power
supply, e.g. by removing the sepa-
rate fuse or by means of a mains
isolator, and check that it is no
longer live.
■Safeguard the system against
reconnection.
Safety instructions
Safety instructions
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3
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■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 pipe-
work.
■Wear suitable personal protective
equipment.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing any work,
touch earthed objects such as heat-
ing or water pipes to discharge
static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function 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 tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate 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 the doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electric shock.
Switch off the heating system at the
external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
5679249

4
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes. Ensure an adequate
supply of combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion 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-seala-
ble.
Extractors
Operating appliances that extract air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of 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 a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5679249

5
1. Information Disposal of packaging ............................................................................ 8
Symbols ................................................................................................. 8
Intended use .......................................................................................... 8
Spare parts lists ..................................................................................... 9
Safety instructions regarding maintenance and cleaning ...................... 9
2. Preparing for installation Boiler room requirements ...................................................................... 10
■Boiler room floor requirements ........................................................... 10
Handling ................................................................................................. 10
■Max. tilting angle during handling ....................................................... 10
■Removing components for access ≤ 900 mm ..................................... 13
Siting requirements ................................................................................ 15
■Compensating for an uneven floor ..................................................... 16
■Minimum clearances, installation room .............................................. 17
3. Installation sequence Fitting the programming unit .................................................................. 18
Fitting the platform ................................................................................. 19
Fitting the bottom thermal insulation ...................................................... 20
Mounting the ash box ............................................................................ 21
Fitting the feed and burn-back protection .............................................. 21
Fitting the ignition unit ............................................................................ 22
Installing the flue gas fan ....................................................................... 23
Connections on the flue gas side ........................................................... 23
Making the connections on the heating water side ................................ 24
■Overview of connections .................................................................... 25
■Installing the return temperature raising facility .................................. 25
■Making the safety connections ........................................................... 25
■Connecting the thermally activated safety valve ................................ 26
■System version ................................................................................... 28
Electrical connections ............................................................................ 29
■Routing cables .................................................................................... 29
■Electrical connection ........................................................................... 30
■Overview of electrical connections ..................................................... 31
Power supply ......................................................................................... 39
■Regulations ......................................................................................... 39
■Connecting the emergency stop mains isolator provided ................... 39
■Recommended power cable ............................................................... 39
Fitting the front casing panels ................................................................ 40
Fitting the side casing panels ................................................................ 42
Fitting the rear casing panels ................................................................. 43
Fitting the top casing panels .................................................................. 44
Affixing the type plate ............................................................................ 44
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 45
5. Codes Code 1 ................................................................................................... 90
■Calling up code 1 ................................................................................ 90
■Overview of coding level 1 .................................................................. 90
■Hardware ............................................................................................ 90
■General ............................................................................................... 94
■Boiler .................................................................................................. 94
■Charging ............................................................................................. 95
■Buffer .................................................................................................. 97
■Additional heat generator ................................................................... 98
■Heating ............................................................................................... 100
■DHW (DHW heater) ............................................................................ 103
■Solar ................................................................................................... 103
Code 2 ................................................................................................... 105
■Calling up code 2 ................................................................................ 105
Index
Index
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6
■Overview of coding level 2 ..................................................................105
■General ............................................................................................... 106
■Boiler .................................................................................................. 106
■Charging ............................................................................................. 108
■Heating ............................................................................................... 109
■DHW (DHW heater) ............................................................................ 111
■Controllers .......................................................................................... 111
6. Diagnosis and service
checks
Service functions ................................................................................... 112
■Calling up the service menu ............................................................... 112
■Exiting the service menu .................................................................... 112
Checking operating states, actuators and sensors ................................ 113
■Calling up the "Information" menu ...................................................... 113
■Calling up the "Diagnosis" menu ........................................................ 113
Checking the outputs (actuators) ........................................................... 113
■The following actuators can be switched "manually" .......................... 113
■Calling up the "Actuator test" menu .................................................... 114
Filling the vacuum module ..................................................................... 115
■Calls up the "Fill vacuum module" menu ............................................ 115
Running the pellet hopper until empty ................................................... 115
■Calling up the "Run pellet hopper until empty" menu ......................... 115
Checking the changeover unit ............................................................... 115
■Calling up the "Changeover unit" menu .............................................. 116
■Icons and text in the menu ................................................................. 116
■Manual operation of changeover unit ................................................. 116
Loading the standard setting ................................................................. 117
■Calling up the "Standard setting" menu .............................................. 117
7. Troubleshooting Fault indicator ........................................................................................ 118
■Checking and acknowledging faults ................................................... 118
■Calling up acknowledged fault messages .......................................... 118
■Calling up fault codes from the fault memory (fault history) ............... 118
■Deleting saved fault codes from the fault memory ............................. 118
Fault displays in plain text ......................................................................119
Fault codes ............................................................................................ 119
8. Maintenance Fuses ..................................................................................................... 126
■Appliance fuse protection (to EN 60127-5) .........................................126
■Checking the fuses ............................................................................. 126
Battery ................................................................................................... 126
High limit safety cut-out ......................................................................... 126
■Triggering the function ........................................................................ 127
■Cancelling the function ....................................................................... 127
Sensors ..................................................................................................127
■Connection ......................................................................................... 127
■Check sensors .................................................................................... 128
Lambda probe ........................................................................................128
■Check Lambda probe ......................................................................... 128
■Checking and calibrating the Lambda probe ...................................... 129
■Connection ......................................................................................... 129
■Lambda probe specification ................................................................130
Extension kit for heating circuit with mixer .............................................130
■Flow temperature sensor .................................................................... 130
■Mixer motor .........................................................................................131
■Specification extension kit .................................................................. 131
9. Function description Display and controls .............................................................................. 132
■Function of "START/STOP" button ..................................................... 132
■Function of the ON/OFF switch on the control unit .............................133
Control functions ....................................................................................133
Index
Index
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7
■Heating water buffer cylinder .............................................................. 133
■Solar circuit control ............................................................................. 135
■Heating circuit control ......................................................................... 135
■Cylinder temperature control .............................................................. 138
Vacuum supply system .......................................................................... 139
■Supply process ................................................................................... 140
Combustion flow chart ........................................................................... 141
10. Connection and wiring dia-
gram
Position of the PCBs ..............................................................................142
■Overview of the PCBs ........................................................................ 143
PCB ZPK 2.03 ....................................................................................... 143
PCB HKK 2.01 ....................................................................................... 146
PCB KSK 2.03 ....................................................................................... 148
Electrical installation .............................................................................. 150
■Requirements ..................................................................................... 150
■Electrical cables/leads ........................................................................ 151
11. Commissioning/service
reports
................................................................................................................153
12. Specification ................................................................................................................154
13. Decommissioning and dis-
posal
Final decommissioning and disposal ..................................................... 158
14. Certificates Declaration of conformity ....................................................................... 159
15. Keyword index ................................................................................................................160
Index
Index (cont.)
5679249

8
Please dispose of packaging waste in line with statu-
tory regulations.
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.
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.
Information
Disposal of packaging
5679249
Information

9
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.
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Safety instructions regarding maintenance and cleaning
Danger
Touching live components can result in life
threatening injuries. After switching off the
ON/OFF switch on the control unit, there are still
live components inside the control unit enclo-
sure.
■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
There is a risk of fire and burns due to hot com-
ponents and cinders.
■Switch off the boiler and let it cool down.
■Carry out maintenance and cleaning work only
on central heating boilers that have cooled
down.
■Allow hot components to cool down before
removing.
■Wear suitable personal protective equipment,
in particular protective gloves.
Danger
Risk of crushing or entanglement due to rotating
and moving parts.
Do not reach in through the maintenance cov-
ers.
Do not remove any protective covers.
Danger
Wood dust, pellet dust, cinders and soot pose a
risk to the eyes, skin and airways.
Wear suitable personal protective equipment,
especially breathing equipment and safety gog-
gles.
Note
Before restarting the heating system, all opened cov-
ers and flaps on the boiler must be closed again.
Note
Observe the country-specific regulations on the dis-
posal of materials, waste and system components.
Information
Intended use (cont.)
5679249
Information

10
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
Partial combustion due to combustion air defi-
ciency can lead to life threatening poisoning
from carbon monoxide.
■Ensure an adequate supply of fresh air.
■Never cover or close vents.
Danger
Easily flammable liquids and materials,e.g.
naphtha/petrol, solvents, cleaning agents, paints
or paper, can cause deflagration and fire.
Do not store easily flammable materials in the
boiler installation room.
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 injury, the following tilt-
ing angles must not be exceeded during transport.
Boiler side Tilting angle
With transport pal-
let
Without transport
pallet
■Front 25° 21°
■Back 24° 25°
■Left 25° 29°
■Right 29° 29°
Preparing for installation
Boiler room requirements
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Installation

11
1. 2. 4x
Fig. 1
1. Remove thermal insulation from under the boiler.
2. Undo the transport brackets.
Preparing for installation
Handling (cont.)
5679249
Installation

12
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 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 later affixed to the left-hand or
right-hand casing panel.
6. Remove the cleaning set from the boiler and keep
it safe.
Preparing for installation
Handling (cont.)
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Installation

13
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 for access ≤ 900 mm
1.
2.
Fig. 5
1. Remove pump head. 2. Pull out plug.
Preparing for installation
Handling (cont.)
5679249
Installation

14
5.
4.
6.
7.
3.
Fig. 6
3. Pull out plug sYS from the power supply.
Note
The electrical cable with plug designation s:G is
not required.
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.)
5679249
Installation

15
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: At least 2.1 m
Preparing for installation
Handling (cont.)
5679249
Installation

16
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.)
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Installation

17
Minimum clearances, installation room
700
800
400
100
A
Fig. 9
Note
Keep area A behind the boiler clear for installation
and maintenance work.
Rated heating output kW 50 60
Wall clearances
a mm 700 700
b mm 400 400
c mm 100 100
d mm 800 800
Preparing for installation
Siting requirements (cont.)
5679249
Installation

18
1.
Fig. 10
!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.
■Do not bend capillaries and observe the mini-
mum permissible radius (5 mm) when bending
them.
■If the capillaries are bent or damaged, the high
limit safety cut-out must be replaced.
1. Fit the programming unit.
Note
Unhook the securing straps of the programming
unit and remove them.
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
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Installation

19
2.
1.
Fig. 11
1. Hook platform into place. 2. Pivot platform downwards.
Installation sequence
Fitting the platform
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Installation

20
Fig. 12
!Please note
Thermal radiation from the boiler can damage
the boiler room floor.
Insert thermal insulation.
Slide the thermal insulation under the boiler as far as it
will go.
Note
Floor pan with thermal insulation: Weight 11 kg
Installation sequence
Fitting the bottom thermal insulation
5679249
Installation