Viessmann VITOLIGNO 300-P Operating instructions

Service instructions
for contractors
VIESMANN
Vitoligno 300-P
Type VL3B
Pellet boiler
For applicability, see the last page
VITOLIGNO 300-P
5692 805 GB 4/2009 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain 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 fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental 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,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances 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 build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 805 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 805 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Codes
Resetting codes to their delivered condition......................................................... 44
Code 1.................................................................................................................. 44
Code 2.................................................................................................................. 50
Service scans
Service functions.................................................................................................. 70
Temperatures, boiler coding card and brief scans............................................... 70
Scanning operating conditions and sensors ........................................................ 75
Troubleshooting
Fault display......................................................................................................... 76
Repairs................................................................................................................. 85
Function description
Display and control elements............................................................................... 103
Control functions.................................................................................................. 103
Vacuum supply system........................................................................................ 118
Pellet combustion sequence chart....................................................................... 119
Designs
Connection and wiring diagram............................................................................ 121
Parts lists............................................................................................................ 126
Commissioning/service reports........................................................................ 136
Specification....................................................................................................... 137
Certificates
Declaration of conformity...................................................................................... 139
Keyword index.................................................................................................... 140
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Fill heating system......................................................... 6
••• 2. Checking all connections on the heating water side
for leaks
•3. Switching the power ON................................................ 6
•4. Language selection........................................................ 10
• • 5. Setting the time and date............................................... 11
•6. Configuring the supply system..................................... 11
•7. Commissioning the supply system.............................. 11
•8. Setting delivery times for fuel supply........................... 12
•9. Matching the control unit to the heating system ........ 12
•10. Checking outputs (actuators) and sensors.................. 29
•11. Adjusting the heating curves........................................ 31
•12. Integrating a control unit into the LON......................... 34
• • 13. Shutting down the system............................................. 36
• • 14. Cleaning the combustion chamber............................... 37
•15. Cleaning the secondary heating surfaces.................... 38
•16. Cleaning the flue gas fan and the Lambda probe........ 39
• • 17. Emptying the ash container (if required)...................... 40
• • 18. Checking the diaphragm expansion vessel and
system pressure............................................................. 41
••• 19. Checking the function of safety valves
•20. Display "Maintenance"................................................... 42
•21. Instructing the system user........................................... 43
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Fill heating system
A
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static system pressure, top
up with nitrogen until the pre-charge
pressure has risen by 0.1 to 0.2 bar.
Adjust the pre-charge pressure
accordingly if it is too high.
2. Open the check valves.
3. Top up your heating system with
water and vent until the filling pres-
sure is 0.1 to 0.2 bar higher than the
pre-charge pressure of the dia-
phragm expansion vessel.
Permiss. operating pressure: 3 bar
Test pressure: 4 bar
4. Mark this pressure at pressure gauge
A.
5. Return the check valves to their oper-
ating position.
Switching the power ON
After switching the power ON, a start-up sequence commences:
■ Select language
■ Set time and date
■ Supply system configuration
■ Supply system commissioning
When configuring the supply system, the
following are available for selection:
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 805 GB

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– "only holding hopper" for pellet sup-
ply from the boiler hopper only (not
shown).
– "Suction system" for pellet supply via
auger discharge from the pellet storage
room and onward transportation via a
vacuum system:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

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– "Auger system" for pellet supply from
the pellet storage room via an auger sys-
tem:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

9
– "Suction system + silo" for pellet
supply from a pellet silo via a vacuum
system:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

10
– "Auger + silo" for pellet supply from a
pellet silo via an auger system:
– "Suction sys. + mole" Available
later.
Menu structure overview:
Vitoligno operating instructions
Language selection
Shortly after switching the power ON, the
display shows "Select language".
Press the following keys:
1. |/~for the required language.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

11
2. dto confirm.
The display shows "Set time
and date".
Setting the time and date
Press the following keys:
1. |/~for the required time.
2. dto confirm.
3. |/~for the required date.
4. dto confirm.
The display shows "Config-
uration Supply system".
Configuring the supply system
At the factory, the supply system is set up to discharge from the pellet hopper only.
Press the following keys:
1. |/~for "Configuration? Yes".
2. dto confirm.
3. |/~for the required supply sys-
tem.
4. dto confirm.
The display shows "Already
set". The display shows
"Commissioning Supply
system".
For an overview of possible supply sys-
tems, see page 51.
Commissioning the supply system
Press the following keys:
1. dto confirm "Commissioning
Supply system".
2. |/~for fuel supply "Enable?
Yes".
The display shows "Fuel
supply enabled".
3. gapprox. 60 s later, the first
pellets trickle into the com-
bustion chamber.
After successful commissioning, the dis-
play shows "Commissioning fin-
ished".
Now the combustion grate is cleaned to
move the remaining pellets into the ash
container.
The display will show the following in
sequence "Please wait", "Grate clean-
ing" and "Empty ash box".
Now empty the ash container to remove
unburned pellets (see page 40).
The heating mode starts automatically
as soon as there is a heat demand.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

12
Note
Now a consumer actuator test should
be carried out (see page 29), even if
heating mode has been started.
Setting delivery times for fuel supply
The factory setting for the fuel delivery time is "Subj. to demand", meaning the fuel
supply system is controlled automatically. Specific times during which there should
be no fuel supply can be selected individually.
Operating instructions Vitoligno 300-P
Matching the control unit to the heating system
Subject to the equipment level, the control unit must be matched to the system. Var-
ious system components are recognised automatically by the control unit and the
relevant codes are adjusted automatically.
Check and possibly adjust all addresses
in Coding 1 (see chapter "Coding 1").
Note
Further optional adjustments are listed in
code 1 and 2.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

13
System version 1
Boiler with DHW cylinder and one or two heating circuits with mixer (optionally
with dual-mode DHW cylinder and solar thermal system)
P
wP
wW
wQ
qE
2
3
wE
4
1
wZ
M M
eW rE
eP rP
eE rR
eQ rQ
qQ
qR
qP
qW
wR
rW
qT
wT
Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
1Vitoligno 300-P
2Vitotronic 200, type FO1
3Outside temperature sensor ATS ! ! ! !
4Boiler water temperature sensor KTS X2 X2 X2 X2
qP DHW cylinder
qQ Cylinder temperature sensor STS % % % %
qW DHW circulation pump ZP sK sK sK sK
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

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Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
qE Circulation pump for cylinder heating
UPSB
sA sA sA sA
qR Cylinder temperature sensor STS
■ with integral solar control unit (sys-
tem with 1 heating circuit with mixer)
%Ê
■ with external solar control unit
Vitosolic (system with 2 heating cir-
cuits with mixer)
wZS2
qT High limit safety cut-out
wP Solar collectors
wQ Collector temperature sensor
■ with integral solar control unit (sys-
tem with 1 heating circuit with mixer)
&Ê
■ with external solar control unit
Vitosolic (system with 2 heating cir-
cuits with mixer)
wZS1
wW Solar-Divicon
wE Solar circuit pump sF wZR1
wR Circulation pump wZR2
wT Automatic thermostatic mixing valve
wZ Vitosolic 100 (for systems with 2 heat-
ing circuits with mixer)
eP Heating circuit I
eQ Flow temperature sensor ? M1 ? M1 ? M1 ? M1
eE Mixer motor DN 20 to 50, R½" to
R1¼"
gS M1 gS M1 gS M1 gS M1
eW Heating circuit pump M1 (heating cir-
cuit I)
sÖ M1 sÖ M1 sÖ M1 sÖ M1
rP Heating circuit II
rQ Thermostat for underfloor heating sys-
tem
■ Immersion thermostat
■ System thermostat
rW Flow temperature sensor ? M2 ? M2
rR Mixer motor DN 20 to 50, R½" to
R1¼"
gS M2 gS M2
rE Heating circuit pump M2 (heating cir-
cuit II)
sÖ M2 sÖ M2
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

15
Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
Accessories (option)
tP KM BUS distributor aVG aVG aVG aVG
tQ Vitotrol 200/300 aVG aVG aVG aVG
tW Radio clock receiver ! ! ! !
tE Vitohome 300 aVG aVG aVG aVG
tR Central fault messaging system S gÖ gÖ gÖ gÖ
X1 Connected in the delivered condi-
tion
wZ... Connection in the Vitosolic 100
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

16
Electrical diagram
ArR eE eW tR qW qE
qQ
qR
eQ
wE rE
/
tP tQ
/tE /
tW 3
/
wQ rW
/
B
APCB A2 connection
BInstall the temperature limiter rQ for
underfloor heating systems or high
limit safety cut-out qT for solar cir-
cuit pump in accordance with the
installation instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

17
System version 2
Boiler with DHW cylinder, heating water buffer cylinder and one or two heating
circuits with mixer (optionally with dual-mode DHW cylinder and solar thermal
system)
P
wP
wW
wQ
qE
2
3
wE
4
1
wZ
M M
eW rE
eP rP
eE rR
eQ rQ
qQ
qR
qP
qW
wR
rW
qT
6
7
8
5
rT
rZ
rU
wT
Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
1Vitoligno 300-P
2Vitotronic 200, type FO1
3Outside temperature sensor ATS ! ! ! !
4Boiler water temperature sensor KTS X2 X2 X2 X2
5 Return temperature raising facility
with
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

18
Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
6 Temperature sensor
7 Boiler circuit pump and sL sL sL sL
8 Thermostatic control valve
qP DHW cylinder
qQ Cylinder temperature sensor STS % % % %
qW DHW circulation pump ZP sK sK sK sK
qE Circulation pump for cylinder heating
UPSB
sA sA sA sA
qR Cylinder temperature sensor STS
■ with integral solar control unit (sys-
tem with 1 heating circuit with mixer)
%Ê
■ with external solar control unit
Vitosolic (system with 2 heating cir-
cuits with mixer)
wZS2
qT High limit safety cut-out
wP Solar collectors
wQ Collector temperature sensor
■ with integral solar control unit (sys-
tem with 1 heating circuit with mixer)
&Ê
■ with external solar control unit
Vitosolic (system with 2 heating cir-
cuits with mixer)
wZS1
wW Solar-Divicon
wE Solar circuit pump sF wZR1
wR Circulation pump wZR2
wT Automatic thermostatic mixing valve
wZ Vitosolic 100 (for systems with 2 heat-
ing circuits with mixer)
eP Heating circuit I
eQ Flow temperature sensor ? M1 ? M1 ? M1 ? M1
eE Mixer motor DN 20 to 50, R½" to
R1¼"
gS M1 gS M1 gS M1 gS M1
eW Heating circuit pump M1 (heating cir-
cuit I)
sÖ M1 sÖ M1 sÖ M1 sÖ M1
rP Heating circuit II
rQ Thermostat for underfloor heating sys-
tem
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

19
Pos. Description Control unit connection with
number of heating circuits
1 2 1 with
solar
2 with
solar
■ Immersion thermostat
■ System thermostat
rW Flow temperature sensor ? M2 ? M2
rR Mixer motor DN 20 to 50, R½" to
R1¼"
gS M2 gS M2
rE Heating circuit pump M2 (heating cir-
cuit II)
sÖ M2 sÖ M2
rT Heating water buffer cylinder
rZ Buffer temperature sensor above lª lª lª lª
rU Buffer temperature sensor below l« l« l« l«
Accessories (option)
tP KM BUS distributor aVG aVG aVG aVG
tQ Vitotrol 200/300 aVG aVG aVG aVG
tW Radio clock receiver ! ! ! !
tE Vitohome 300 aVG aVG aVG aVG
tR Central fault messaging system S gÖ gÖ gÖ gÖ
wZ... Connection in the Vitosolic 100
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB

20
Electrical diagram
ArR eE eW tR qW qE
qQ
qR
eQ
wE rE
/
tP tQ
/tE /
tW 3
/
wQ rW
/
7
rZ
rU
B
APCB A2 connection
BInstall the temperature limiter rQ for
underfloor heating systems or high
limit safety cut-out qT for solar cir-
cuit pump in accordance with the
installation instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 805 GB