Viessmann Vitoplus 300 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitoplus 300
Type VP3A, 12.9/19.3 kW, 16.1/23.5 kW
Wall mounted oil fired condensing boiler
for the combustion of low sulphur fuel oil DIN 51603-EL-1
with integral boiler control unit
For applicability, see the last page
VITOPLUS 300
5692 536 GB 7/2005 Please keep safe

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental 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.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life‐threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 536 GB

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
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non‐authorised compo-
nents and non‐approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 536 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 38
Code 2........................................................................................................ 41
Resetting codes to the delivered condition ................................................. 60
Service scans
Service level overview ................................................................................ 61
Temperatures, boiler coding card and brief scans ....................................... 61
Checking outputs (relay test) ...................................................................... 64
Scanning operating conditions and sensors ................................................ 64
Troubleshooting
Fault display ............................................................................................... 67
Calling up fault codes from the fault memory (fault history) .......................... 68
Fault codes ................................................................................................ 68
Repairs ...................................................................................................... 75
Function description
Control ...................................................................................................... 85
Extensions for external connections (accessories) ...................................... 89
Control functions ........................................................................................ 91
Remote control DIP switch .......................................................................... 97
Designs
Connection and wiring diagrams –internal connections .............................. 98
Connection and wiring diagrams –external connections.............................. 99
Parts lists .................................................................................................. 101
Specification............................................................................................. 114
Certificates
Declaration of conformity ............................................................................ 115
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 116
Keyword index .......................................................................................... 117
Index
4
Index
5692 536 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler .................................................................. 8
•03. Venting the heating system............................................... 9
•04. Filling the siphon with water............................................. 9
•05. Checking the power supply connection
• • 06. Setting the time and date (if required)........................... 9
•07. Changing the language at the control unit .................. 10
••• 08. Function sequence and possible faults ....................... 10
• • 09. Adjusting the standard burner settings ....................... 11
• • 10. Adjusting the oil pressure and checking the
vacuum ..................................................................................... 13
• • 11. Adjusting the air volume (static burner pressure) . . . 14
• • 12. Cleaning and testing the flame monitor ....................... 16
•13. Cleaning the burner ............................................................. 17
•14. Adjusting or replacing the nozzle and checking the
ignition electrodes................................................................ 18
• • 15. Cleaning and replacing the oil pump filter, if
required ................................................................................... 20
• • 16. Checking the heating surfaces for contamination . . . 21
• • 17. Cleaning the heating surfaces ......................................... 22
• • 18. Checking the condensate drain and cleaning the
siphon........................................................................................ 23
• • 19. Checking the neutralising system (accessories) ..... 23
• • 20. Checking the active charcoal filter (accessories) . . . . 24
••• 21. Checking the diaphragm expansion vessel and
system pressure
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 536 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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••• 22. Checking all connections on the primary side for
leaks
••• 23. Checking the burner (recording values on page
108 of the commissioning report)
••• 24. Checking the function of all safety valves
••• 25. Checking the tightness of electrical connections
•26. Matching the control unit to the heating system ...... 24
•27. Integrating the control unit into the LON system...... 30
•28. Implementing a user check (in conjunction with
the LON system) .................................................................... 31
•29. Adjusting heating curves................................................... 32
•30. Instructing the system user .............................................. 36
•31. Scanning and resetting the "Maintenance" display 36
Steps –initial start-up, inspection and . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 536 GB

Filling the heating system
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. !Please note
Unsuitable fill water
increases the level of depos-
its and corrosion and may
lead to boiler damage.
&Thoroughly flush the entire
heating system prior to fill-
ing it with water.
&Only use fill water of pota-
ble quality.
&Soften fill water harder
than 3.58 mmol/l.
&An anti-freeze additive sui-
table for heating systems
can be added to the fill
water.
Drain the heating system via boiler
fill & drain valve A. (minimum sys-
tem pressure > 0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
changeover valve will still be in its
central position, and the system will
be completely filled.
3. If the control unit had already been
switched ON before filling began:
Start the control unit and in code 1,
set coding address "2F:2" (see
page 38).
The display shows "Filling"
The diverter valve is in its central
position.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 536 GB

4. Continue to fill the system.
5. Close boiler fill & drain valve A.
Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose between
top valve Band a drain outlet.
3. Open valves Aand B, and vent
at mains pressure until no sound of
escaping air can be heard.
4. Close valves Aand Band open
the primary shut-off valves.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 536 GB

Venting the heating system
1. Start the control unit.
2. Activate the venting program via
coding address "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 38.
For function and sequence of the
venting program, see page 92.
When the venting program is
enabled, the display shows
"Venting".
3. Check the system pressure.
Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fill the siphon with water.
3. Fit siphon Aand secure with the
retaining clip.
Setting the time and date (if required)
Note
During commissioning, or after prolonged time out of use, it may be necessary
to set the time and date, if the time flashes in the display.
1. Set the correct time with a/b.2. Confirm with d.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 536 GB

3. Set the current date with a/b.4. Confirm with d.
Changing the language at the control unit
1. Press c.
The display shows "Select heating
circuit".
2. Press d.
3. After approx. 4 s press c.
4. Select the required language with
b.
5. Confirm with d.
Function sequence and possible faults
For further details regarding faults, see page 68.
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Yes
Oil pre-heating
starts No
after approx. 10
min
Check the oil pre-
heater, cables
and plug-in con-
nections
Fault
E6
Yes
The fan starts
after max. 10 min
No Fault Check the oil pre-
heater, fan,
cables and plug-
in connections
(the oil preheater
has not switched
through; the tem-
perature is not
achieved)
F9
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 536 GB

Yes
The air pressure
switch responds No After approx. 51 s Check the air pressure switch,
cables and plug-
in connections
Fault
F5
Yes
Ignition and oil
pump motor start No Check the ignition module and oil
pump motor,
cables and plug-
in connections
Yes
The solenoid
valves open No Fault Check the oil sup-
ply; check the so-
lenoid valves
F4
Yes
Flame signal pre-
sent
Symbol A
No Fault Checking the
flame monitor
F4
Yes
Burner in opera-
tion
Adjusting the standard burner settings
Standard burner settings
Note
Check that the service instructions are valid for the relevant burner (see applic-
ability on the last page and the serial no. on the boiler type plate).
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 536 GB

AFlue gas test port
Rated output kW 12.9/19.3 16.1/23.5
Burner stage Stage 1 Stage 2 Stage 1 Stage 2
Rated output
at burner stage kW 12.9 19.3 16.1 23.5
Oil burner nozzle Type 80°H LE V 80°H LE V
Make:Danfoss Gph 0.40 0.50
Oil pressure ap-
prox. *1bar 8.0-10.5 15.0-17.5 8.0-11.0 13.5-16.0
Max. permissible
vacuum
in the oil feed line
bar 0.35 0.35 0.35 0.35
Oil flow rate kg/h 1.05 1.58 1.31 1.92
approx. l/h 1.24 1.86 1.57 2.30
Static burner pres-
sure approx.
&Operating phase
&Ignition phase
mbar
mbar
8.0-9.5
11
16.0-17.5
11
8.7-10.7
11
17.5-19.5
11
CO2content ap-
prox.
&Test value excl.
cap panel
% 12.2-13.0 12.2-13.0
&Test value incl. cap
panel
% 12.7-13.5 12.7-13.5
Flame monitor set-
ting
5 5
Nozzle gap "a" mm 3.0
+0.2/-0.3
1.5
+0.2/-0.3
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 536 GB
*1Due to nozzle tolerances and varying oil characteristics, the oil pressure may vary from
the values shown.

Rated output kW 12.9/19.3 16.1/23.5
(see page 18)
!Please note
An incorrectly adjusted nozzle gap "a" can result in irregular operation of
the burner and even a fault shutdown.
Always maintain the stated dimension and check in accordance with the
details on page 18.
Adjusting the oil pressure and checking the vacuum
Oil pump; make: Danfoss,
type BFP 52
1. Insert the pressure gauge (range
0 - 25 bar) into test port "P"Aand
the vacuum gauge (range 0 -
1 bar) into test port "V"B.
Note
Seal the pressure and vacuum
gauges only with copper or alumi-
nium gaskets or with O-rings.
Never use tape to seal these
joints.
2. Start the boiler.
3. Press Kand dsimultaneously
for approx. 2 s.
"Relay test" is shown in the dis-
play.
4. Select burner stage 1 with aand
b.
"Burner st 1 ON" is shown on the
display.
5. Where vacuum measures higher
than 0.35 bar, check the filter for
contamination or check the pipe
route.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 536 GB

6. If required, adjust the oil pressure
for stage 1 at pressure adjusting
screw Cof the oil pump (for stan-
dard values, see page 12).
7. Check the actual emission values
after adjusting the oil pressure.
8. Select burner stage 2 with aand
b.
"Burner st 1 + 2 ON" is shown on
the display.
9. If required, adjust the oil pressure
for stage 2 at pressure adjusting
screw Dof the oil pump.
10. Check the actual emission values
after adjusting the oil pressure.
11. After testing, press d.
Adjusting the air volume (static burner pressure)
1. Start the boiler.
2. Remove plug Afrom the test port.
3. Connect the U-shaped pressure
gauge to test port A.
4. Press Kand Fsimultaneously
until "Speed stage 1" and a value
between 1 and 255 is displayed.
5. Change the value with a/buntil
the static burner pressure dis-
played on the U-shaped pressure
gauge and the CO2flue gas content
correspond to the values in the
table on page 12.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 536 GB

6. Confirm the set value with d.
Note
The control unit changes automati-
cally to burner stage 2. The display
shows "Speed stage 1 + 2 " and a
value between 1 and 255.
7. Repeat steps 4 and 5 for burner
stage 2.
8. Check the set values.
9. Seal test connector Aagain with
the previously removed plug.
Note
Do not seal the connector next to
test connector A.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 536 GB

Cleaning and testing the flame monitor
1. Pull flame monitor Afrom the
retainer for inspection and clean-
ing.
2. Test the function:
Tests to be
carried out
Required re-
sponse
1. Start the burner
with the flame
monitor cov-
ered
Fault shutdown
at the end of the
safety period
"TSA"
2. Start the burner
with the flame
monitor ex-
posed to exter-
nal light
Fault shutdown
after a max. of
40 s
3. Burner opera-
tion with simu-
lated flame
blow-off. For
this, cover the
flame monitor
during opera-
tion and leave
in that state.
Restart followed
by a fault shut-
down at the end
of the safety per-
iod "TSA"
3. Fit the flame monitor.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 536 GB

Cleaning the burner
1. Undo nuts, remove the lid with
mixer equipment Aand secure in
the maintenance position.
2. Pull the leads off ignition electro-
des B.
3. Undo Allen screw Cand remove
rifling facility D.
4. Clean the restrictor, metering ring,
ignition electrodes and the flame
monitor tube.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 536 GB

Adjusting or replacing the nozzle and checking the ignition
electrodes
1. Undo nozzle E(whilst holding the
oil preheater). Prevent the forma-
tion of bubbles.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 536 GB

2. Insert a new LE nozzle E(whilst
holding the oil preheater).
Select the nozzle in accordance
with the details on page 13.
!Please note
Only use nozzles marked
"V" (on the hexagon) (see
Fig.).
3. Insert rifling facility Das far as
possible. Align ignition electrodes
Bin accordance with the drilled
holes towards the cable entries.
Install the oil burner nozzle cen-
trally in the restrictor.
4. Secure Allen screw Cof the rifling
facility. Check nozzle gap "a".
!Please note
An incorrectly adjusted noz-
zle gap "a" can result in irre-
gular operation of the burner
and even a fault shutdown.
Rated output kW 12.9/19.3 16.1/23.5
Nozzle gap "a" (see page 18) mm 3.0
+0.2/-0.3
1.5
+0.2/-0.3
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 536 GB

Cleaning and replacing the oil pump filter, if required
Oil pump; make: Danfoss, type BFP 52
AFilter plug
BO-ring (replace)
CFilter (replace)
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 536 GB