Viessmann VITOLADENS 300-C Service Instructions Manual

Service instructions

for contractors

VIESMANN

Vitoladens 300-C

Type VC3, 12.9 to 28.9 kW

Oil condensing boiler

with integral boiler control unit

For applicability, see the last page

VITOLADENS 300-C

5692 774 GB 11/2009 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

5692 774 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 774 GB

4

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 5

Further details regarding the individual steps....................................................... 7

Codes

Code 1.................................................................................................................. 37

Code 2.................................................................................................................. 40

Resetting codes to their delivered condition......................................................... 54

Service scans

Service level overview ......................................................................................... 55

Temperatures, boiler coding card and brief scans .............................................. 55

Checking outputs (relay test)................................................................................ 57

Scanning operating conditions and sensors ........................................................ 58

Troubleshooting

Fault display......................................................................................................... 60

Fault codes .......................................................................................................... 61

Repairs................................................................................................................. 68

Function description

Control unit........................................................................................................... 76

Control functions.................................................................................................. 77

Remote control DIP switches............................................................................... 83

Designs

Connection and wiring diagram – internal connections ....................................... 85

Parts lists............................................................................................................ 90

Commissioning/service reports........................................................................ 97

Specification....................................................................................................... 98

Certificates

Declaration of conformity...................................................................................... 99

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 99

Keyword index.................................................................................................... 101

Index

5692 774 GB

5

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Filling the heating system.............................................. 7

••• 2. Checking all connections on the heating water side

for leaks

•3. Venting the boiler........................................................... 8

•4. Venting the heating system

• • 5. Draining the heating system (if required)..................... 9

•6. Filling the siphon or neutralising system (accessory)

with water........................................................................ 9

•7. Checking power supply connection

• • 8. Setting the time and date (if required).......................... 10

•9. Changing the language at the control unit................... 11

••• 10. Function sequence and possible faults....................... 11

• • 11. Removing the front panel.............................................. 13

• • 12. Opening the boiler door................................................. 14

• • 13. Cleaning the heating surfaces....................................... 14

• • 14. Closing the boiler door.................................................. 17

•15. Cleaning the burner........................................................ 18

•16. Replacing the nozzle and checking or adjusting the

ignition electrodes.......................................................... 19

•17. Burner installation.......................................................... 20

• • 18. Cleaning and replacing the oil pump filter, if

required .......................................................................... 20

• • 19. Checking gaskets and thermal insulation

components.................................................................... 21

••• 20. Checking electrical connections for tightness

• • 21. Checking the condensate drain and cleaning the

siphon (if installed)......................................................... 23

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 774 GB

6

Commissioning steps

Inspection steps

Maintenance steps Page

• • 22. Checking the neutralising system (accessories)........ 23

• • 23. Checking the active charcoal filter (accessories)....... 23

••• 24. Checking the diaphragm expansion vessel and

system pressure

• • 25. Adjusting the standard burner settings....................... 23

• • 26. Adjusting the oil pressure and checking the vacuum 25

• • 27. Adjusting the air volume (static burner pressure)...... 26

• • 28. Fitting the front panel..................................................... 27

••• 29. Checking the function of safety valves

•30. Matching the control unit to the heating system ........ 27

•31. Adjusting the heating curves........................................ 30

•32. Linking the control unit to the LON.............................. 33

•33. Instructing the system user........................................... 35

•34. Scanning and resetting the "Service" display............. 36

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5692 774 GB

7

Filling the heating system

!Please note

Unsuitable fill water increases the level of deposits and corrosion and may

lead to boiler damage.

■ Thoroughly flush the entire heating system prior to filling it with water.

■ Only use fill water of potable quality.

■Soften fill water with hardness exceeding 16.8 °dH (3.0 mol/m3), e.g. using

a small softening system for heating water (see Viessmann Vitoset price

list).

■ An antifreeze additive suitable for heating systems can be mixed with the

fill water. The antifreeze manufacturer must verify its suitability.

1. Check the pre-charge pressure of the

diaphragm expansion vessel.

2. Remove front insulation shell A.

3. Open air vent valve B.

4. Fill the heating system at the fill

valve C in the heating return. (Mini-

mum system pressure 0.8 bar.)

5. Close air vent valve B when no

more air is being expelled.

6. Close boiler fill valve C.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 774 GB

8

Venting the boiler

1. Close the shut-off valves on the heat-

ing water side.

2. Remove front insulation shell A (if

already fitted).

3. Connect the drain hose on air vent

valve B with a drain.

4. Open valves B and C and vent

using mains pressure until no more

air noise is audible.

5. Close valves B and C and open

the heating water shut-off valves.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

9

Draining the heating system (if required)

ADrain valve

Filling the siphon or neutralising system (accessory) with water

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

10

Pull the supply hose A (siphon or neu-

tralising system) from the boiler conden-

sate drain B and fill with a little water.

Setting the time and date (if required)

Note

■ During commissioning, or after a pro-

longed time out of use, it may be nec-

essary to reset the time and date, if the

time flashes in the display.

■ When the unit is first taken into opera-

tion the display is in German (default

language setting):

Time (see step 1)

Uhrzeit

Date (see step 2)

Datum

Sa

Press the following keys:

1. a/bfor the current time.

2. dto confirm; "Datum" is dis-

played.

3. a/bfor the current date.

4. dto confirm.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

11

Changing the language at the control unit

Note

When the unit is first taken into operation

the display is in German (default lan-

guage setting):

Select heating circuit (see step 1.)

Heizkreis wählen

1

z

Outside temperature (see step 3.)

Außentemperatur

i°C

13

Press the following keys:

1. c"Heizkreis wählen" (select

heating circuit) is displayed.

2. dto confirm; wait approx. 4 s.

3. cpress this button again,

"Außentemperatur" (outside

temperature) is displayed.

4. bfor the required language.

5. dto confirm.

Function sequence and possible faults

Display screen Measures

Control unit

issues heat

demand

No Increase set value

and ensure heat is

drawn off

Yes

Oil preheating

starts No

after approx.

10 min

Check the oil pre-

heater, cables and

plug-in connectors

Fault

E6

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

12

Yes

Fan starts after no

more than

10 min.

Green LED on

ignition trans-

former flashes.

No Fault Check the oil pre-

heater, fan, cables

and plug-in con-

nectors

(the oil preheater

has not switched

through; the tem-

perature is not ach-

ieved)

F9

Yes

The air pressure

switch responds

No after approx. 51 s Check the air pres-

sure switch, cables

and plug-in con-

nectors

Fault

F5

Yes

Ignition and oil

pump motor start

No Check the ignition

module and oil

pump motor,

cables and plug-in

connectors

Yes

The solenoid

valves open

No Fault Check the oil sup-

ply; check the sol-

enoid valves

F4

Yes

Flame signal

present

Symbol A

No Fault Check ignition

electrodes, elec-

trode gaps and

connecting lines

F4

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

13

Yes

Burner in opera-

tion.

The green LED on

the ignition trans-

former is perma-

nently on (a flame

is recognised).

For further details regarding faults, see

page 61.

Removing the front panel

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

14

Opening the boiler door

1. Remove cables running to the fan

A from their retainers.

2. Remove screws and open the boiler

door.

Cleaning the heating surfaces

!Please note

To prevent damage to the heat exchanger,

only clean with the cleaning equipment available as accessory

Danger

Cleaning work may lead to eye injuries.

Wear protective goggles.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

15

1. Clean the biferral heating surface

(front area) with brush A.

2. Clean the biferral heating surface and

the stainless steel heat exchanger

with a vacuum cleaner. Angled noz-

zle B is available as an accessory.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

16

3. Pull condensate hose E from the

boiler.

4. Push on-site hose D on the connec-

tor and route to a suitable vessel

C.

5. Flush stainless steel heat exchanger

with water F.

6. Check the condensate drain and

hose E for contamination.

Clean with a bottle brush, if required.

Never damage the hose with the

brush.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

17

7. Reconnect condensate hose E.8. Insert combustion chamber to the

end-stop.

Closing the boiler door

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

18

Cleaning the burner

1. Undo screws, remove the lid with

mixing facility B and secure in the

maintenance position.

Note

If the mixing facility B cannot be

pulled out, open the boiler door and

push the mixing facility B by apply-

ing light pressure against the pres-

sure disc.

2. Pull the cables from the oil preheater

A and the ignition electrodes E.

3. Undo Allen screw C and remove

rifling facility D.

4. Clean the restrictor, dosing ring and

ignition electrodes.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

19

Replacing the nozzle and checking or adjusting the ignition elec-

trodes

2.5 mm

a

1. Undo nozzle F whilst holding the oil

preheater. Prevent the formation of

bubbles.

2. Insert a new LE nozzle F (whilst

holding the oil preheater).

Select the nozzle in accordance with

the details on page 24.

3. Insert rifling facility D as far as pos-

sible. Align ignition electrodes E in

accordance with the drilled holes

towards the cable entries. Install the

oil burner nozzle centrally into the

restrictor.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

20

4. Secure Allen screw C of the rifling

facility. Check nozzle gap "a". !Please note

An incorrectly adjusted nozzle

gap "a" can result in irregular

operation of the burner and

even a fault shutdown.

Rated output kW 12.9/19.3 16.1/23.5 19.3/28.9

Nozzle gap "a"

(see page 19) mm 3.0 +0.2/-0.3 1.5 +0.2/-0.3 1.5 +0.2/-0.3

Burner installation

Tighten screws/bolts across and click

cables back into place.

Cleaning and replacing the oil pump filter, if required

Danfoss oil pump, type BFP 52

A

B

C

AFilter plug

BO-ring (replace)

CFilter (replace)

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 774 GB

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Viessmann VITOLADENS 300-C Service Instructions Manual

Viessmann VITOLADENS 300-C Service Instructions Manual

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