Viessmann VITOLIG 300 Service Instructions Manual
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Viessmann VITOLIG 300 Service Instructions Manual

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

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Summary of Contents for Viessmann VITOLIG 300

  • Page 1 VIESMANN Service instructions for contractors Vitolig 300 Type VL3A Pellet boiler VITOLIG 300 Please keep safe. 5692 618 GB 8/2005...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 For replacements, use only ori- Repair work ginal spare parts from Viessmann or those which are Please note approved by Viessmann. Repairing components which fulfil a safety function can com- promise the safe operation of your heating system.

  • Page 4: Table Of Contents

    Index Index Commissioning and adjustment Calling up the service level ................. Changing parameters and calling up operating information......Commissioning ................... Actuator test ....................Operating and service documents ............... Instructing the system user ................. Inspection and maintenance 1. Shutting down the heating system ............10 2.

  • Page 5: Commissioning And Adjustment

    Commissioning and adjustment Index (cont.) See also the operating instruc- tions. Calling up the service level At the service level of the control unit, system parameters can be changed and commissioning steps or actuator tests can be carried out. For information regarding the menu controls, see the operating instructions. 1.

  • Page 6: Changing Parameters And Calling Up Operating Information

    Commissioning and adjustment Changing parameters and calling up operating information 1. In menu option "Parameter" high- 2. Change the required parameter light the required sub-option with with "+" or " ". " " or " " and confirm with "select". 3.
  • Page 7 Commissioning and adjustment Changing parameters and calling up operating . . . (cont.) Suction turbine with 3 wands Suction turbine with 2 wands Suction turbine agitator Runtime of the suction turbine Set the runtime of the suction turbine Delivered condition: 50 s subject to the length of the supply line Setting range: 20 to 70 s and the head.

  • Page 8: Commissioning

    Commissioning and adjustment Commissioning In menu option "Commissioning" high- light the required sub-option with " " or " " and confirm with "select". The following functions can be adjusted under menu option "Commissioning": Supply auger The supply auger is started for 6 min. Supply The supply and every wand is started with a purging program subject to the...

  • Page 9: Operating And Service Documents

    Commissioning and adjustment Operating and service documents File all parts lists, operating and ser- vice instructions in the folder 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.

  • Page 10: Inspection And Maintenance

    Inspection and maintenance 1. Shutting down the heating system Please note Operating instructions Hot gases can escape from the combustion chamber. Only open the combustion chamber door when the system ON/OFF switch has been switched off. 2. Combustion chamber Note Clean the boiler with a vacuum clea- ner and the cleaning implements sup- plied.
  • Page 11 Inspection and maintenance 2. Combustion chamber (cont.) 1. Check the combustion chamber 5. Remove flying ash from combus- door for leaks. If in doubt, test with tion chamber temperature sensor a paper strip. A paper strip (approx. B (behind the reversing plate). 20 mm wide) that has been jammed into the door gap must not be able 6.

  • Page 12: Burner

    Inspection and maintenance 3. Burner 1. Remove cone A with cleaning tool B, then remove deposits with a spatula from cone A. 2. Remove primary air spigot C and carefully clean the holes. The holes must be completely free from obstruction.

  • Page 13: Induced Draught Fan And Secondary Heating Surface

    Inspection and maintenance 4. Induced draught fan and secondary heating surface 1. Flip up control unit A. 5. Cleaning the flue pipe. 2. Release four wing nuts and remove 6. Vacuum the upper area of second- fan unit B. Check the gasket for ary heating surface E.

  • Page 14: Ash Chamber, Secondary Heating Surface

    Inspection and maintenance 4. Induced draught fan and secondary heating . . . (cont.) 8. Test the function of the heating sur- face cleaner by pressing the reset button (starting the system). 5. Ash chamber, secondary heating surface 1. Vacuum the ash chamber. 3.

  • Page 15: Ash Removal

    Inspection and maintenance 5. Ash chamber, secondary heating surface (cont.) 4. Rake ash out. 6. Install clean-out cover C and lock into place. 5. Vacuum the remaining fly ash. 7. Insert ash deflector panel A. 6. Ash removal 1. Open l.h. door. 5.

  • Page 16: Pellet Hopper

    Inspection and maintenance 7. Pellet hopper 1. Open casing door A. 5. Remove dust from the supply unit and from flap D. 2. Position a suitable container B below the opening. 6. Check flap D for ease of opera- tion. It must lie flush over the entire 3.

  • Page 17: Boiler Control

    Inspection and maintenance 8. Boiler control 1. Remove lid A and flip up control 5. Check the electrical plug-in con- unit cover B. nections for tight fit. 2. Undo screws and remove lid C. 6. Check the routing of electrical cables/leads.

  • Page 18: Water Container Of The Back Burning Protection

    Inspection and maintenance 9. Water container of the back burning protection 1. Check the water level on level 3. Remove plug C and fill with water. indicator A and top up, if required. 4. Refit plug C and fit front panel B. 2.

  • Page 19: Changeover Unit Of The Automatic Charging System

    Inspection and maintenance 10. Changeover unit of the automatic charging system 1. Check changeover unit A for 2. With the wand changeover, control leaks and ease of operation. all wands and supply pellets by way of testing. Operating instructions 11. Checking the diaphragm expansion vessel and system pres- sure Observe the diaphragm expansion vessel manufacturer s instructions.

  • Page 20: Checking The Function Of The Thermally Activated Safety Valve

    12. Checking the function of the thermally activated safety valve Only for the Vitolig 300 with 21.0 and 25.9 kW. 1. Activate the valve of the thermally 2. In case of a low throughput, check...

  • Page 21: Heating Test

    Inspection and maintenance 14. Heating test 1. Start up the boiler and check the 2. Check the setting and function of combustion. the boiler control unit. Flue gas limits content: 8 to 14 % by vol. CO content with 8% CO : max.

  • Page 22: Troubleshooting Fault Messages

    Troubleshooting Fault messages Fault messages during operation These fault messages are indicated by codes "FE" or "In". The boiler returns to operation when the relevant fault has been removed. Note After a fault has been removed, press the reset button. Operating instructions Display Explanation/Cause/Effect...
  • Page 23 Troubleshooting Fault messages (cont.) Display Explanation/Cause/Effect Remedy indication In 581 Hopper almost empty (the level Start the pellet supply or wait for/ switch has responded). change the enable time. The boiler continues to heat until the remaining fuel has been used up. In 582 Hopper empty;...
  • Page 24 Troubleshooting Fault messages (cont.) Display Explanation/Cause/Effect Remedy indication AL 037 The pellet supply flap does not Open the pellet hopper, clean close after the supply is com- the flap and return into an opera- pleted. tion state (see page 16). No pellets reach the hopper.
  • Page 25 Troubleshooting Fault messages (cont.) Display Explanation/Cause/Effect Remedy indication AL 133 High limit safety cut-out has re- See "Steps when the boiler over- sponded. Boiler water tempera- heats" in the operating instruc- ture in excess of 100 °C. tions. The boiler completely burns the available fuel;...

  • Page 26: Repairs

    Troubleshooting Repairs Checking the boiler water temperature sensor and the flue gas temperature sensor 1. Check the sensor resistance. 2. Disconnect cores from the sensor, Boiler water temperature sensor if actual values deviate severely Resistance: NTC 5 k from the curve, repeat sensor mea- surements and compare with the actual temperature (for scanning, Temperature...

  • Page 27: Connection And Wiring Diagrams

    Connection and wiring diagrams Connection and wiring diagrams Standard control...
  • Page 28 Connection and wiring diagrams Connection and wiring diagrams (cont.) Power supply unit + 12 V DC Supply auger capacitor High limit safety cut-out, boiler Main device fuse 6.3 ATr 100 °C Relay for suction turbine High limit safety cut-out, sup- Mains filter ply auger 100 °C Motor for supply auger...
  • Page 29 Connection and wiring diagrams Connection and wiring diagrams (cont.) Induced draught fan motor Terminal block 12 V/ext. Motor for heating surface clea- Heating demand and change- over unit limit switch Motor for ash removal Connection plug, suction tur- Motor changeover unit bine Combustion chamber door Display unit, control unit...
  • Page 30 Connection and wiring diagrams Connection and wiring diagrams (cont.) Supply unit, pumps, mixer motor and switch A Power supply 230 V ~ C Low water indicator or escape B Emergency stop switch heating switch system D Motor changeover unit E Suction turbine...
  • Page 31 Connection and wiring diagrams Connection and wiring diagrams (cont.) F Heating circuit pump 1 N Module PCB G Cylinder primary pump O Buffer primary controller, terminal H Mixer motor 1 block K Heating circuit pump 2 P Heating circuit 2 terminal block L Mixer motor 2 R Heating circuit 1 terminal block M Boiler circuit pump...
  • Page 32 Connection and wiring diagrams Connection and wiring diagrams (cont.) A External heat demand K Buffer cylinder temperature sen- B Changeover unit limit switch C Flow temperature sensor 1 L Module PCB D Cylinder temperature sensor M Buffer primary controller, terminal E Outside temperature sensor block F Remote control 1...

  • Page 33: Parts Lists Parts List

    Parts lists Parts list Information regarding ordering Burner complete spare parts Combustion chamber tempera- Quote the part and serial no. (see ture sensor type plate) and the item number of the Lid, ash container required part (as per this parts list). Lid, rear Obtain standard parts from your local Lid, secondary heating surface...
  • Page 34 Parts lists Parts list (cont.) Lever, bottom 1240 Motor, ash removal Charge door complete 1250 Motor, ash shaker Interface BUML TTL 1260 Motor automatic changeover Thermal insulation panel unit High temperature insulating 1270 Fan motor brick, fan box 1280 Proximity switch Thermal insulation, fan lid 1290 Proximity switch Thermal insulation retainer, fan...
  • Page 35 Parts lists Parts list (cont.) 1660 Auger tube 2040 Deflector panel 1670 Olive 2050 Changeover unit with 3 suction 1680 Worm drive clip wands 1690 Screw, heating surface cleaner 2060 Control panel, bottom part 1700 Screw, bearing 2070 Connection, collector box 1710 Protective pipe (cyclone) 1720 Side panel...
  • Page 36 Parts lists Parts list (cont.) 2170 Wagoblock 261 8 part 2300 Service instructions 2180 Wagoblock 261 8 part 2310 Installation and service instruc- 2190 Wagoblock 8 PIN tions, heating circuit controller 2280 Installation instructions 2320 Installation instructions, storage 2290 Operating instructions room accessories...
  • Page 37 Parts lists Parts list (cont.)
  • Page 38 Parts lists Parts list (cont.)
  • Page 39 Parts lists Parts list (cont.)
  • Page 40 Parts lists Parts list (cont.)
  • Page 41 Parts lists Parts list (cont.)
  • Page 42 Parts lists Parts list (cont.)
  • Page 43 Parts lists Parts list (cont.)

  • Page 44: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Commissioning Service Service date: Service Service Service date: Service Service Service date: Service Service Service date: Service Service Service date:...

  • Page 45: Specification

    Specification Specification Rated output range 2.9 to 4.3 to 15 6.3 to 21 7.5 to 25.9 Required draught mbar 0.05 0.05 0.05 0.05 Flue gas Average temperature (gross) at the upper rated out- °C at partial load (33% of °C the upper rated output) content % by vol.

  • Page 46: Certificates

    Certificates Declaration of conformity We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm as sole responsible body that the product Vitolig 300, type VL3A complies with the fol- lowing standards: EN 303-5 EN 304 EN 50 165 EN 60 335...

  • Page 47: Keyword Index

    Keyword index Keyword index Actuator test Maintenance ........
  • Page 48 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

This manual is also suitable for:

Vl3a

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