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 891 GB 6/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
!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 contractors.
■ 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:
■ National installation requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ Isolate the system from the power sup-
ply (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 unau-
thorised reconnection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
Before beginning work, earthed
objects, such as heating or water
pipes, must be touched to dissi-
pate any static charge.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
5692 891 GB

3
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 891 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......................................................... 54
Code 1.................................................................................................................. 54
Code 2.................................................................................................................. 60
Service scans
Service functions.................................................................................................. 80
Temperatures, boiler coding card and brief scans............................................... 80
Scanning operating conditions and sensors ........................................................ 85
Troubleshooting
Fault display......................................................................................................... 86
Repairs................................................................................................................. 95
Function description
Display and control elements............................................................................... 114
Control functions.................................................................................................. 114
Allocation of heating circuits to remote control..................................................... 129
Vacuum supply system........................................................................................ 130
Pellet combustion sequence chart....................................................................... 131
Designs
Connection and wiring diagram............................................................................ 133
Parts lists............................................................................................................ 139
Commissioning/service reports........................................................................ 150
Specification....................................................................................................... 151
Certificates
Declaration of conformity...................................................................................... 153
Keyword index.................................................................................................... 154
Index
Index
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5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 6
••• 2. Checking all connections on the heating water side
for leaks
•3. Completing the commissioning checklist
•4. Switching the power on................................................. 6
•5. Language selection........................................................ 11
• • 6. Setting the time and date............................................... 12
•7. Configuring the supply system..................................... 12
•8. Commissioning the supply system.............................. 12
•9. Setting supply times for fuel supply (with vacuum
system)............................................................................ 13
•10. Matching the control unit to the heating system ........ 13
•11. Checking outputs (actuators) and sensors.................. 39
•12. Adjusting the heating curves........................................ 41
•13. Integrating a control unit into the LON......................... 44
• • 14. Shutting down the system............................................. 46
• • 15. Cleaning the combustion chamber............................... 47
•16. Cleaning secondary heating surfaces.......................... 48
•17. Cleaning the flue gas fan and Lambda probe.............. 49
• • 18. Emptying the ash container (if required)...................... 50
• • 19. Checking the diaphragm expansion vessel and
system pressure............................................................. 51
••• 20. Checking the function of safety valves
•21. Display "Maintenance"................................................... 52
•22. Instructing the system user........................................... 53
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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6
Filling the heating system
A
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
If the pre-charge pressure is lower
than the static system pressure, top
up with nitrogen until the pre-charge
pressure has risen 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 charge 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 the charge 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 commissioning 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
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– "Only holding hopper" for pellet sup-
ply only from the boiler hopper with man-
ual charging (not shown).
– "Suction system" for pellet supply via
screw conveyor discharge from a pellet
store and onward transportation via a
vacuum system:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

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– "Auger system" for pellet supply via
screw conveyor supply system from a
pellet store:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

9
– "Suction system + silo" for pellet
supply from a pellet silo via vacuum sup-
ply system:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

10
– "Auger + silo" for pellet supply from a
pellet silo via screw conveyor supply sys-
tem:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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11
– "Suction system + mole" for pellet
supply via mole from a pellet store and
onward transportation via a vacuum sup-
ply system:
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.
2. dto confirm.
The display shows "Set time
and date".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

12
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 62.
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 after the first pel-
lets trickle into the combus-
tion 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 50).
Heating mode starts automatically as
soon as there is a heat demand.
Note
Now a consumer actuator test should
be carried out (see page 39), even if
heating mode has been started.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

13
Setting supply times for fuel supply (with vacuum system)
The factory setting for the fuel supply time is "Subj. to demand", meaning the 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 Code 1 (see chapter "Code 1").
Note
Further adjustment options are listed in
codes 1 and 2.
System version 1 — Vitoligno 300-P with one or two heating circuits with mixer,
DHW cylinder (with optional dual mode DHW cylinder and solar thermal sys-
tem)
Function description
Heating circuits eP and rP are regulated
by control unit Vitotronic 200 (type FO1)
2 of the Vitoligno 300-P 1. The boiler
will only start if there is a demand for the
DHW cylinder or a heating circuit. The
time program for heating mode and heat-
ing up the DHW cylinder qP is set at the
boiler control unit.
Return temperature raising facility
The boiler is equipped with a return tem-
perature raising facility. The boiler water
temperature is monitored. If the mini-
mum temperature is not reached, the
flow rate is reduced by the connected
mixers eR/rR.
The heating circuit pumps eE/rE start
only if the boiler water temperature lies
above the set flow temperature.
DHW heating by the Vitoligno 300-P
The DHW is heated up if the actual tem-
perature falls below the set DHW tem-
perature at cylinder temperature sensor
qT, subject to cylinder heating being
enabled by the time program. The boiler
water temperature is regulated to the set
cylinder temperature + 15 K or the mini-
mum boiler water temperature of 60 °C,
and circulation pump for cylinder heating
qE starts if the boiler water temperature
lies 7 K above the actual cylinder water
temperature.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

14
If the heating circuits are regulated via
Vitotronic 200 (type FO1) 2, heating
circuit pumps M1 eE and M2 rE stop,
and mixers M1 eR and M2 rR are
closed, subject to absolute priority being
enabled.
With modulating priority (recommen-
ded), heating circuit pumps M1 eE and
M2 rE remain switched on, and mixers
M1 eR and M2 rR are closed far enough
for the set boiler water temperature
required for cylinder heating to be ach-
ieved. DHW cylinder qP and heating cir-
cuits eP and rP will then be heated
simultaneously.
Heating mode
In accordance with the control unit used,
the flow temperature of heating circuits
eP and rP is modulated subject to the
outside temperature. The boiler water
temperature is regulated 8 K higher than
the set flow temperature or the minimum
boiler water temperature of 60 °C.
The heating circuit pump is switched on
via the heating circuit pump logic, provi-
ded there is a heat demand.
DHW heating by the solar thermal
system with Vitosolic (two heating
circuits)
For systems with two heating circuits
with mixer or if additional solar control
unit functions are required (e.g. heating
the solar preheat stage and switching the
transfer pump), use a Vitosolic solar con-
trol unit.
If Vitosolic 100 (type SD1) wZ is connec-
ted via the KM BUS to Vitotronic 200
(type FO1) 2, solar control unit infor-
mation (e.g. collector temperature, cylin-
der temperature, solar circuit pump
hours run and solar yield) can be dis-
played on the Vitotronic 200 or Vitotrol
300.
If the temperature differential between
collector temperature sensor wQ and cyl-
inder temperature sensor qT exceeds
the start temperature differential, solar
circuit pump wE starts, and DHW cylin-
der qP is heated up.
The pump is switched off if:
■ The actual temperature drops below
the stop temperature differential
■ The electronic temperature limit is
exceeded
■ The temperature selected at the high
limit safety cut-out (if installed) is
reached
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

15
Hydraulic installation scheme ID: 4605024_1001_02
--2/21--
--26/S2--
--2/5--
----26/R1--
--26/R2--
--26/S1--
--230V--
--230V--
--R1--
--R2--
--S1--
--S2--
KW
WW
--
--
--2/28--
--KM BUS--
/
--21--
--28--
--1--
--5--
--KM BUS--
--2M1-- --2M2--
--20M1--
--52M1--
--20M2--
--52M2--
--2/52M1--
--2/20M1--
--2/2M1--
--2/52M2--
--2/20M2--
--2/2M2--
--2/20M2--
--2/1--
60
40
61
42
43
44
60
30
32
33
34
21 20
22
26
23
25
12
16
24
13
10 14
15
11
8
45
2
9
1
Required equipment
ID: 4605024_1001_02
Pos. Description
Heat source
1Vitoligno 300-P with
2Vitotronic 200, type FO1
rT Outside temperature sensor ATS
8Safety equipment block with safety valve
9Expansion vessel
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

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ID: 4605024_1001_02
Pos. Description
DHW heating by the boiler
qP DHW cylinder
qQ Cylinder temperature sensor STS
qW DHW circulation pump ZP
qE Circulation pump for cylinder heating UPSB
DHW heating by the solar thermal system
qR Dual mode DHW cylinder
qT Cylinder temperature sensor SOL
qZ High limit safety cut-out STB
wP Solar collectors
wQ Collector temperature sensor KOL
wW Solar-Divicon
wE Solar circuit pump R1
wR Circulation pump
wT Automatic thermostatic mixing valve
wZ Vitosolic 100, type SD1
wU Junction box
eP Heating circuit I
eQ Extension kit for one heating circuit with mixer with
eW ■ Flow temperature sensor VTS (contact sensor)
and
eR ■ Mixer motor DN 20 to 50, R½ to R1¼
or
eW Flow temperature sensor VTS M1 (heating circuit I)
■ Contact temperature sensor or
■ Immersion temperature sensor
and
eR Mixer motor M1 for flanged mixer and plug-in connector
eE Heating circuit pump HKP M1 (heating circuit I)
or
Divicon
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

17
ID: 4605024_1001_02
Pos. Description
rP Heating circuit II
rQ Extension kit for one heating circuit with mixer with
rW ■ Flow temperature sensor VTS (contact sensor)
and
rR ■ Mixer motor DN 20 to 50, R½ to R1¼
or
rW Flow temperature sensor VTS M2 (heating circuit II)
■ Contact temperature sensor or
■ Immersion temperature sensor
and
rR Mixer motor M2 for flanged mixer and plug-in connector
rE Heating circuit pump HKP M2 (heating circuit II)
or
Divicon
Accessories
zP Vitotrol 200A
or
Vitotrol 300A
zQ Thermostat for underfloor heating system
■ Immersion thermostat
■ System thermostat
zW KM BUS distributor
zE Vitohome 300
zR Central fault message system S
zT Radio clock receiver
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

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Electrical installation scheme ID: 4605024_1001_02
HKP M2
230 V/ 50 Hz
M2
L
NM
1~
UPSB
ZP
230 V/ 50 Hz
2
28
21
52
20
40
44
43
12
13
61
20
230V, 50Hz
50
64
HKP M1
20
33
M1
M1
52
34
M1
M2
M2
12
11 4
3
2
1
S1
S2
L
N 20
R1
R2
STB
SOL
17
16
13
R2
N
14
R1
N 18
230 V/ 50 Hz
15
KOL
M
1~
21
19
26
145
27
21
15
24
16
23
Low voltage
ATS
STS
VTS M1
2
5
1
32
11
45
KM BUS
145
62
145
145
60
145
63
/
65
/
VTS M2
242
M1
M2
L
NM
1~
M
1~
N
LM
1~
L
N
N
L
N
L
NM
1~
M
1~
N
M
1~
1
3
2
1
3
2
1
3
2
1
3
2
1
3
2
1
3
2
1
3
2
1
3
2
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

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System version 2 — Vitoligno 300-P with one or two heating circuits with mixer,
heating water buffer cylinder and DHW cylinder (with optional dual mode DHW
cylinder and solar thermal system)
Function description
The heating circuits eP and rP are regu-
lated by control unit Vitotronic 200, type
FO1 2 of the Vitoligno 300-P 1. The
boiler will only start if there is a demand
for the DHW cylinder or a heating circuit.
The time program for heating mode and
heating up the DHW cylinder qP is set at
the boiler control unit.
Heating up the heating water buffer
cylinder and raising the return tem-
perature
The boiler and boiler circuit pump 5
start when the actual temperature at buf-
fer temperature sensor tQ falls below
the set temperature for heating circuits
eP and rP, or DHW cylinder qP. The
boiler shuts down and the boiler circuit
pump runs on for approx. 10 min when
the actual temperature at buffer temper-
ature sensor tW falls below the set tem-
perature for the heating circuits. Mixing
valve 4 in the return temperature rais-
ing facility holds the boiler return water at
a minimum of 45 °C. Set the water cir-
culation volume in the boiler circuit of the
Vitoligno 300-P so that a temperature
spread of 15 K between the boiler flow
and return results at the rated boiler
heating output.
DHW heating by the Vitoligno 300-P
The DHW is heated up if the actual tem-
perature falls below the set DHW tem-
perature at cylinder temperature sensor
qQ, subject to cylinder heating being
enabled by the time program. The boiler
water temperature is regulated to the set
cylinder temperature + 15 K or the mini-
mum boiler water temperature of 60 °C.
Circulation pump for cylinder heating
qE starts when the heating water buffer
cylinder temperature (top) lies 7 K above
the cylinder temperature.
If the heating circuits are regulated via
the Vitotronic 200 (type FO1) 2, heat-
ing circuit pumps M1 eE and M2 rE stop,
and mixers M1 eR and M2 rR are
closed, subject to absolute priority being
enabled (recommended).
With modulating priority, heating circuit
pumps M1 eE and M2 rE remain
switched on, and mixers M1 eR and M2
rR are closed far enough for the set
boiler water temperature required for cyl-
inder heating to be achieved. DHW cyl-
inder qP and heating circuits eP and
rP will then be heated simultaneously.
Heating mode
In accordance with the control unit used,
the flow temperature of heating circuits
eP and rP is modulated subject to the
outside temperature. The boiler water
temperature is regulated 8 K higher than
the set flow temperature or the minimum
boiler water temperature of 60 °C.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB

20
The heating circuit pump is switched on
via the heating circuit pump logic, provi-
ded there is a heat demand. Upon
demand, the boiler is operated with the
required set boiler water temperature or
the minimum boiler water temperature of
60 °C.
The boiler shuts down if neither the DHW
cylinder nor the heating circuits issue
any more demands.
DHW heating by the solar thermal
system with Vitosolic
For systems with two mixer heating cir-
cuits or if additional solar control func-
tions are required (e.g. heating the solar
preheat stage and switching the transfer
pump), use a Vitosolic solar control
unit.
If the Vitosolic 100 (type SD1) is connec-
ted via the KM BUS to the Vitotronic 200
(type FO1), solar control unit information
(e.g. collector temperature, cylinder tem-
perature, solar circuit pump hours run
and solar yield) can be displayed on the
Vitotronic 200 or Vitotrol 300A.
If the temperature differential between
collector temperature sensor wQ and cyl-
inder temperature sensor qT exceeds
the start temperature differential, solar
circuit pump wE starts, and DHW cylin-
der qR is heated up.
The pump is switched off if:
■ The actual temperature drops below
the stop temperature differential
■ The electronic temperature limit is
exceeded
■ The temperature selected at the high
limit safety cut-out (if installed) is
reached
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 891 GB