Viessmann Vitolig 300 Service Instructions Manual Download Page 1

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VIESMANN

Service instructions

for contractors

Vitolig 300
Type VL3A

Pellet boiler

VITOLIG 300

5692 618 GB

8/2005

Please keep safe.

Summary of Contents for Vitolig 300

Page 1: ...VIESMANN Service instructions for contractors Vitolig 300 Type VL3A Pellet boiler VITOLIG 300 5692 618 GB 8 2005 Please keep safe ...

Page 2: ...ll 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 lead to serious injury Never smoke Prevent naked flam...

Page 3: ...ion 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 or conversions can compromise sa...

Page 4: ...oval 15 7 Pellet hopper 16 8 Boiler control 17 9 Water container of the back burning protection 18 10 Changeover unit of the automatic charging system 19 11 Checking the diaphragm expansion vessel and system pressure 19 12 Checking the function of the thermally activated safety valve 20 13 Checking the mixer for obstructions and leaks 20 14 Heating test 21 15 Checking the draught 21 Troubleshootin...

Page 5: ...he operating instructions 1 Press Menu The display shows user level and service level 2 With V or v select menu option service level and confirm with select 3 Hold down key 5 s longer than 5 s The display shows the sub options Parameter Commis sioning and Actuator test 4 With V or v select menu option and confirm with select 5 Exit the menu with back This will also occur automatically after 45 s I...

Page 6: ...is displayed in kg h Hysteresis burner ON Switching hysteresis for burner con trol Delivered condition 5 K Setting range 0 to 20 K Maximum value of the set temperature Maximum set boiler water tempera ture in heating mode Delivered condition 75 C Setting range 60 to 75 C Set temperature ext heat demand Set boiler water temperature in case of external heat demand Delivered condition 75 C Setting ra...

Page 7: ...ash the grate in the burner pot is shaken by a motor in specified intervals The number of shakes per event can be adjusted Rated output kW 9 9 and 15 0 21 0 and 25 9 Opera tion Burnout Opera tion Burnout Delivered condition 20 40 20 30 Setting range 10 30 15 60 10 30 15 60 Ventilation air extract air damper The runtime of a connected ventila tion air or extract air damper can be adjusted at the co...

Page 8: ...ystem Actuator test In menu option Actuator test high light the required sub option with V or v and confirm with select Note The functions are respectively started for 1 min The control unit carries out a self test following the termination of the actuator test The following functions can be con trolled Induced draught fan Supply auger Grate shaking Ignition element Ash removal Heating surface cle...

Page 9: ... and hand this over to the system user Instructing the system user The system installer must hand the operating instructions to the system user and instruct him her in the opera tion of the system Operating and service documents 9 Commissioning and adjustment 5692 618 GB ...

Page 10: ...ombustion chamber door when the system ON OFF switch has been switched off Operating instructions 2 Combustion chamber Note Clean the boiler with a vacuum clea ner and the cleaning implements sup plied 1 Shutting down the heating system 10 Inspection and maintenance 5692 618 GB ...

Page 11: ...the door hinges 3 Lift reversing plate A at the back and remove at a slant towards the front 4 Clean reversing plate A 5 Remove flying ash from combus tion chamber temperature sensor B behind the reversing plate 6 Refit reversing plate A 7 Clean drop chute C with cleaning tool D 8 Check the condition of the combus tion chamber cover panels 2 Combustion chamber cont 11 Inspection and maintenance 56...

Page 12: ...l B and remove Remove ash residues from the grate plate and from the centre holes 4 Clean burner pot E and grate inside the burner pot with a spatula Vacuum burner pot E and primary air pipe in the centre of the burner pot 5 Assemble in reverse order Ensure that the shaker handle locks into the recess of grate plate D and that web F on the burner pot locks into the recess on cone A 3 Burner 12 Ins...

Page 13: ...patula Vacuum fly ash from the impeller lid and fan box 4 Lift the fan box D at the front and lift out 5 Cleaning the flue pipe 6 Vacuum the upper area of second ary heating surface E 7 Assemble in reverse order Note Tighten the wing nuts diagonally 4 Induced draught fan and secondary heating surface 13 Inspection and maintenance 5692 618 GB ...

Page 14: ...button starting the system 5 Ash chamber secondary heating surface 1 Vacuum the ash chamber 2 Remove ash deflector panel A 3 Turn locking clip B to the left and remove clean out cover C 4 Induced draught fan and secondary heating cont 14 Inspection and maintenance 5692 618 GB ...

Page 15: ...er slightly to the left and remove 4 Empty the ash container 5 Check gaskets between ash container and boiler and the gasket on the lid of the ash container for tight fit and condition 6 Refit the ash container in reverse order 7 Check the function of the automatic ash removal For this press the reset button and the door contact switch in the combustion chamber door 5 Ash chamber secondary heating...

Page 16: ... the current fill level 4 Remove pellet residues and dust from the hopper Note Pellet dust is purely organic and can be disposed of with biowaste 5 Remove dust from the supply unit and from flap D 6 Check flap D for ease of opera tion It must lie flush over the entire sealing face 7 Refit clean out cover C and close door A 7 Pellet hopper 16 Inspection and maintenance 5692 618 GB ...

Page 17: ...f required clean the PCB with compressed air or a vacuum clea ner 5 Check the electrical plug in con nections for tight fit 6 Check the routing of electrical cables leads These must neither touch hot components e g fan box nor be squashed in 7 Close control unit again 8 Boiler control 17 Inspection and maintenance 5692 618 GB ...

Page 18: ...and top up if required 2 Slightly lift the front panel of supply unit B and remove 3 Remove plug C and fill with water 4 Refit plug C and fit front panel B 9 Water container of the back burning protection 18 Inspection and maintenance 5692 618 GB ...

Page 19: ...est on a cold system 1 Drain the system or close the cap valve on the diaphragm expansion vessel and reduce the pressure until the pressure gauge indi cates 0 2 If the inlet pressure of the dia phragm expansion vessel is lower than the static system pressure top up with sufficient nitrogen to raise the inlet pressure above 0 1 to 0 2 bar the static system pres sure The static pressure corresponds ...

Page 20: ... 9 kW 1 Activate the valve of the thermally activated safety valve Push red cap A against the valve Water must flow from the valve 2 In case of a low throughput check the heat exchanger for scaling and sludge deposits Clean if required 13 Checking the mixer for obstructions and leaks 1 Check the mixer for ease of opera tion 2 Check the mixer for leaks Replace the O rings in case of leaks 11 Checki...

Page 21: ... 8 CO2 max 200 ppm with 14 CO2 max 1000 ppm Flue gas temperature max 200 C 2 Check the setting and function of the boiler control unit 15 Checking the draught Check the draught inside the flue pipe for required draught see specifica tions on page 45 14 Heating test 21 Inspection and maintenance 5692 618 GB ...

Page 22: ...ver FE 281 Flue gas temperature sensor faulty The flue gas temperature can not be displayed No effect on the operation Check the flue gas temperature sensor see page 26 FE 381 Hopper empty Start the pellet supply or wait for change the enable time The fully automatic pellet sup ply is switched off The pellet supply has stopped as it is currently outside the se lected enable time FE 382 The level s...

Page 23: ...by code AL After the relevant fault has been removed press the reset button prior to start ing the boiler again Display indication Explanation Cause Effect Remedy AL 005 Grate shaker blocked Clean the burner pot see page 12 Grate shaker motor or limit switch faulty The boiler completely burns the available fuel Replace motor or limit switch AL 006 Supply auger motor faulty The boiler completely bu...

Page 24: ...burns the available fuel Check the boiler water tempera ture sensor see page 26 AL 078 Combustion chamber tempera ture sensor faulty The boiler completely burns the available fuel Replace the combustion cham ber temperature sensor AL 085 Safety sensor at the supply auger faulty The boiler completely burns the available fuel Replace the safety sensor AL 128 Supply auger blocked by a for eign body T...

Page 25: ...mber and remove all pellets from the burner pot Press reset Press reset again if the fuel does not ignite AL 171 is shown pellets have been da maged through the high tem peratures inside the supply auger AL 171 Maximum heat up time ex ceeded No flame has built after 8 min heat up time Clean the burner pot see page 12 Ignition element faulty The heat up process is terminated Replace ignition elemen...

Page 26: ... 80 1 24 0 87 Flue gas temperature sensor Resistance PT 1000 Temperature in C Pressure drop in kΩ 20 60 90 120 150 1 08 1 23 1 35 1 46 1 57 2 Disconnect cores from the sensor if actual values deviate severely from the curve repeat sensor mea surements and compare with the actual temperature for scanning see operating instructions 3 Depending on the result replace the lead or the sensor Repairs 26 ...

Page 27: ...Standard control Connection and wiring diagrams 27 Connection and wiring diagrams 5692 618 GB ...

Page 28: ...it safety cut out sup ply auger 100 C C1 Fan capacitor 3 μF C2 Supply auger capacitor F1 Main device fuse 6 3 ATr K1 Relay for suction turbine L1 Mains filter M0a Motor for supply auger M0b Shaker motor Connection and wiring diagrams cont 28 Connection and wiring diagrams 5692 618 GB ...

Page 29: ...hangeover unit motor X STB Connection plug high limit safety cut out supply auger 100 C XV Terminal block 12 V ext Heating demand and change over unit limit switch XZ Connection plug suction tur bine X1 Display unit control unit X2 Power supply 230 VAC X3 High limit safety cutout boiler auger X4 Supply auger X5 Shaking X6 Ignition X7 Heating surface cleaner and ash removal X8 Fan motor capacitor X...

Page 30: ...nd switch A Power supply 230 V B Emergency stop switch heating system C Low water indicator or escape switch D Motor changeover unit E Suction turbine Connection and wiring diagrams cont 30 Connection and wiring diagrams 5692 618 GB ...

Page 31: ...p 2 L Mixer motor 2 M Boiler circuit pump N Module PCB O Buffer primary controller terminal block P Heating circuit 2 terminal block R Heating circuit 1 terminal block Temperature sensors and remote control Connection and wiring diagrams cont 31 Connection and wiring diagrams 5692 618 GB ...

Page 32: ...perature sensor F Remote control 1 G Flow temperature sensor 2 H Remote control 2 K Buffer cylinder temperature sen sor L Module PCB M Buffer primary controller terminal block N Heating circuit 2 terminal block O Heating circuit 1 terminal block Connection and wiring diagrams cont 32 Connection and wiring diagrams 5692 618 GB ...

Page 33: ...270 Finger guard 280 Level switch panel 285 Dummy coupling with lock 290 Stud bearing 300 Stud 8H11 x 4 x 10 310 Fire protection 320 Fire protection bellows 330 Burner complete 340 Combustion chamber tempera ture sensor 350 Lid ash container 360 Lid rear 370 Lid secondary heating surface 380 Lid secondary heating surface bottom 390 Lid back wall 400 Lid collector box cyclone 410 Lid control panel ...

Page 34: ...90 Magnet complete 1200 Test port closure 1210 Micro switch 1220 Micro switch 1230 Module connection PCB 1240 Motor ash removal 1250 Motor ash shaker 1260 Motor automatic changeover unit 1270 Fan motor 1280 Proximity switch 1290 Proximity switch 1300 Power supply unit 1310 Key w o pull supply auger 1320 PCB FMF 1330 PCB retainer 1340 Deflector 1350 Primary air spigot ceramic 1370 Cleaning edge dro...

Page 35: ...unit 2010 U bracket 7 x 8 mm 2020 Union nut 2030 Union nut 8 mm 2040 Deflector panel 2050 Changeover unit with 3 suction wands 2060 Control panel bottom part 2070 Connection collector box cyclone 2080 Connection rail heating surface cleaner 2090 Casing changeover unit 2100 Locking arm control panel 2110 Front 2200 Water container 2210 Elbow bottom 2220 Elbow strain relief 2230 Rocker switch 2240 Z...

Page 36: ...ock 8 PIN 2280 Installation instructions 2290 Operating instructions 2300 Service instructions 2310 Installation and service instruc tions heating circuit controller 2320 Installation instructions storage room accessories Parts list cont 36 Parts lists 5692 618 GB ...

Page 37: ...Parts list cont 37 Parts lists 5692 618 GB ...

Page 38: ...Parts list cont 38 Parts lists 5692 618 GB ...

Page 39: ...Parts list cont 39 Parts lists 5692 618 GB ...

Page 40: ...Parts list cont 40 Parts lists 5692 618 GB ...

Page 41: ...Parts list cont 41 Parts lists 5692 618 GB ...

Page 42: ...Parts list cont 42 Parts lists 5692 618 GB ...

Page 43: ...Parts list cont 43 Parts lists 5692 618 GB ...

Page 44: ...ce Service date by Service Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by Commissioning service reports 44 Commissioning service reports 5692 618 GB ...

Page 45: ...rated output C 76 82 84 85 CO2 content by vol 11 7 13 3 14 0 14 8 Mass flow rate at the upper rated out put kg h 24 8 33 1 44 6 52 6 at partial load 33 of the upper rated output kg h 9 3 12 4 16 7 19 7 Specification 45 Specification 5692 618 GB 1Observe when sizing the chimney 2Calculation values for sizing the flue gas system to EN 13384 3Actual flue gas temperature as average gross value to EN 3...

Page 46: ...00 type VL3A complies with the fol lowing standards EN 303 5 EN 304 EN 50 165 EN 60 335 In accordance with the following Directives this product is _ designated 73 23 EEC 89 336 EEC 98 37 EC Allendorf 05 08 05 Viessmann Werke GmbH Co KG pp Manfred Sommer Declaration of conformity 46 Certificates 5692 618 GB ...

Page 47: ...diagram 27 F Fault messages 22 Faults 22 Flue gas temperature sensor 26 G Grate shakings 7 H Heating test 21 Hysteresis burner on 6 M Maintenance 10 Maximum set boiler water temperature 6 O Operating information 6 P Parts list 33 Pellet dust 16 Pellet hopper 16 Pellet supply 6 R Repairs 26 Runtime suction turbine 7 Runtime ventilation air damper 7 S Set temperature ext heat demand 6 Spare parts 33...

Page 48: ...GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com ...

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