Viessmann VITOLIGNO 300-C Installation And Service Instructions Manual
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Viessmann VITOLIGNO 300-C Installation And Service Instructions Manual

Pellet boiler 60 to 70 kw
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Viesmann
Installation and service instructions
for contractors
Vitoligno 300-C
Type VL3C
Pellet boiler
60 to 70 kW
For applicability, see the last page
VITOLIGNO 300-C
Please keep safe.
5777173 GB/en 9/2017

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  • Page 1 Viesmann Installation and service instructions for contractors Vitoligno 300-C Type VL3C Pellet boiler 60 to 70 kW For applicability, see the last page VITOLIGNO 300-C Please keep safe. 5777173 GB/en 9/2017...
  • Page 2 Prior to commencing work, touch earthed lidate our warranty. objects such as heating or water pipes, to dis- For replacements, use only original spare parts charge static loads. supplied or approved by Viessmann.
  • Page 3 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell flue gas Danger Leaking or blocked flue systems, or an inade- Danger quate supply of combustion air can cause life Flue gas can lead to life threatening poisoning. threatening poisoning from carbon monoxide in ■...
  • Page 4 Index Index 1. Information Disposal of packaging ................Symbols ....................Intended use ..................Safety instructions regarding maintenance and cleaning ...... 2. Preparing for installation Boiler room requirements ..............Boiler room floor requirements ............■ Handling ....................Max. tilting angle during handling ............■...
  • Page 5 Index Index Additional heat generator ..............106 ■ Heating ....................108 ■ DHW ....................111 ■ Solar ....................111 ■ Code 2 ....................113 Calling up code 2 ................113 ■ Overview of coding level 2 ..............113 ■ General ....................113 ■...
  • Page 6 Index Index (cont.) Replacing the ignition element ...............138 9. Parts lists Overview of assemblies .................139 Thermal insulation assembly ..............140 Boiler overview ..................143 Combustion chamber assembly ............144 Ignition and drive systems assembly ............. 146 Doors assembly ..................148 Ash removal assembly ................150 Cleaning assembly ................
  • Page 7 Please dispose of packaging waste in line with statu- DE: Use the disposal system organised by tory regulations. Viessmann. AT: Use the ARA statutory disposal system (Altstoff Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor.
  • Page 8 Information Intended use The appliance is only intended to be installed and Any usage beyond this must be approved by the man- operated in sealed unvented heating systems that ufacturer in each individual case. comply with EN 12828, with due attention paid to the associated installation, service and operating instruc- Incorrect usage or operation of the appliance (e.g.
  • Page 9 Preparing for installation Boiler room requirements A separate dry boiler room must be provided for the Danger system. No combustible materials may be stored in the Suffocation hazard due to carbon monoxide pro- boiler room. duced during incomplete combustion due to lack of combustion air.
  • Page 10 Preparing for installation Handling (cont.) 1. Remove thermal insulation from under the boiler. 2. Undo the transport brackets. Fig. 1...
  • Page 11 Preparing for installation Handling (cont.) 3. Lift boiler off the pallet using flexible sling gear attached to the transport lug. Fig. 2 4. Lift boiler off the pallet and transport to installation location with a pallet truck or forklift truck. 5.
  • Page 12 Preparing for installation Handling (cont.) Note The access to the installation room must be at least 800 mm wide. If the width of the access is less than 900 mm, first remove certain components, as described in chapter "Removing components for access 900 mm"...
  • Page 13 Preparing for installation Handling (cont.) Fig. 6 3. Disconnect plug from the power supply. 5. Lift out the feather key. Note 6. Remove chain tensioner. The cable with plug designation is not needed. 7. Remove chain by opening the master link. 4.
  • Page 14 Preparing for installation Handling (cont.) 180° Fig. 7 8. Dismantle gearwheel. Note After siting the boiler in its final position, refit the com- 9. Insert ash removal screw and pull out on the oppo- ponents in reverse order. site side of the boiler. Siting requirements ■...
  • Page 15 Preparing for installation Siting requirements (cont.) Compensating for an uneven floor Fig. 8 Note Any unevenness of the boiler room floor can be com- pensated via the 4 adjusting screws on the boiler.
  • Page 16 Preparing for installation Siting requirements (cont.) Minimum clearances for pellet supply with pellet hopper Fig. 9 Note Keep area behind the boiler clear for installation and maintenance work. Rated heating output Notes Wall clearances 450 (1215) 450 (1215) 200 sufficient if dimension c ≥...
  • Page 17 Preparing for installation Siting requirements (cont.) Minimum clearances for pellet supply via flexible screw conveyor Fig. 10 Pellet discharge or connector at the pellet silo Rated heating output Wall clearances 200 (965) 200 (965) Note Note Dimensions in brackets are measured up to the boiler Observe the minimum bending radius of the flexible casing.
  • Page 18 Preparing for installation Siting requirements (cont.) Further details regarding positioning: See the technical guide for the boiler Minimum clearances Fig. 11 Pellet discharge or connector at the pellet silo Hose with screw conveyor Rated heating output Minimum clearances, flexible screw conveyor Min.
  • Page 19 Installation sequence Fitting the programming unit Fig. 12 Please note 1. Fit the programming unit. An incorrectly routed display ribbon cable can cause system damage. Note ■ Do not kink or crush the ribbon cable. Unhook and remove the securing straps on the ■...
  • Page 20 Installation sequence Fitting the platform Fig. 13 1. Hook platform into place. 2. Pivot platform downwards.
  • Page 21 Installation sequence Fitting the bottom thermal insulation Fig. 14 Please note Note Heat radiating from the boiler can damage the Floor pan with thermal insulation: Weight 11 kg boiler room floor. Use thermal insulation. Slide the thermal insulation under the boiler as far as it will go.
  • Page 22 Installation sequence Fitting the feed Fig. 15 1. Screw in the adjustable foot at the support plate 5. Install the light barrier sensor (receiver) on the front (foot) of the feed. of the boiler. Plug in the connecting cable on the light barrier sensor and secure.
  • Page 23 Installation sequence Installing the flue gas fan Fig. 16 1. Insert flue gas fan and secure with screws. 3. Insert flue gas temperature sensor and secure with screw. 2. Screw Lambda probe into place. Note Use the Lambda probe key provided.
  • Page 24 Installation sequence Fitting the casing panel Before installing the pellet hopper or the flexible screw conveyor drive, fit the bottom casing panel at the back of the boiler. Fig. 17...
  • Page 25 Installation sequence Boiler version with pellet hopper Installing the pellet hopper Fig. 18 1. Place the pellet hopper on the rotary lock valve. 2. Secure with M 6 x 16 hexagon screws. Do not fully tighten the screws as yet. Note The pellet hopper can also be rotated by 180°...
  • Page 26 Installation sequence Boiler version with pellet hopper (cont.) 10 Nm Fig. 19 3. Align the pellet hopper so that the flange and cast 5. Visual inspection casing of the rotary lock valve are flush. Check through the opening that the pellet hopper is correctly positioned.
  • Page 27 Installation sequence Boiler version with pellet hopper (cont.) Installing the pellet hopper sensor 5-10 Fig. 20 Vacuum hose return Pellet supply 1. Remove the pellet hopper cover. 2. Screw in the pellet sensor. Note Screw in to a depth of 5 10 mm.
  • Page 28 Installation sequence Boiler version with pellet hopper (cont.) Fig. 21 1. Fitting the cover 3. Route the cables. Note Note The cover can be rotated in 90° increments and See chapter "Routing cables", page 42. then installed. 2. Connect the pellet sensor lead and route it through the cable channel on the pellet hopper.
  • Page 29 Installation sequence Boiler version with pellet hopper (cont.) Break off the casing panels at the perforations and, if necessary, deburr the breaking point. Note Only for boilers with 60 70 kW boiler output. – Fig. 23 1. Screw in the adjustable feet. 4.
  • Page 30 Installation sequence Boiler version with pellet hopper (cont.) Fig. 24 6. Fit the tunnel panels. Note 6 screws for boilers with 60 70 kW boiler output. ■ – ■ 4 screws for boilers with 80 kW boiler output. ≥ Installing the vacuum module Installation and service instructions, vacuum module...
  • Page 31 Installation sequence Boiler version with flexible screw conveyor Installing the adaptor 10 Nm Fig. 25 1. Centre the adaptor on the rotary lock valve. 2. Tighten the screws.
  • Page 32 Installation sequence Boiler version with flexible screw conveyor (cont.) Installing the feed casing Fig. 26 1. Screw in adjustable feet. 6. Fit the drive unit on the adaptor and position it at the required angle. Tighten the screws, torque 2. Fit the joining plates. 10 Nm.
  • Page 33 Installation sequence Boiler version with flexible screw conveyor (cont.) Fig. 27 07. Run the cables through the diaphragm grommet. 09. Fit the tunnel panels. 08. Secure the right-hand casing panel with screws 10. Route the cables. and join both casing panels with hexagon screw M 6 x 16.
  • Page 34 90° 90° Fig. 28 Flange at the room discharge or pellet silo (Viessmann product range) 1. Push the flexible screw conveyor onto the shaft 3. Only for pellet storage room with room discharge: end as far as the support ring.
  • Page 35 Installation sequence Boiler version with flexible screw conveyor (cont.) 4. Mount the room discharge adaptor with gasket to 5. Push hose over the flexible screw conveyor onto the discharge connector of the room discharge or the room discharge adaptor and secure with a the pellet silo.
  • Page 36 Installation sequence Boiler version with flexible screw conveyor (cont.) Fitting the flexible screw conveyor to the drive unit Fig. 30 1. Undo screw on the motor shaft. 5. Tighten the screws on the screw conveyor fixing tab. 2. Pull motor shaft out downwards. 6.
  • Page 37 Installation sequence Boiler version with flexible screw conveyor (cont.) Fitting the hose support 1. Secure the foot to the support plate with 2 screws and nuts (supplied). 2. Clamp the hose support between the floor and the supply hose. 3. Secure the supply hose to the hose support with hose clips (supplied).
  • Page 38 Installation sequence Installing the ash box Danger Risk of severe burns due to hot surfaces. Only carry out work when the boiler is cold. Danger There is a risk of falling due to slipping and trip- ping on the ash box. Do not stand on the ash box.
  • Page 39 Installation sequence Connections on the flue gas side (cont.) 1. Install the flue pipe with a rise to the chimney (pref- erably 45°). Flue pipe (internal diameter): 150 mm Max. flue pipe length: 3000 mm Note Never push the flue pipe too far into the chimney. 2.
  • Page 40 Installation sequence Making the connections on the heating water side Overview of connections Note Route water pipes so that all casing panels are acces- sible and can be removed for maintenance. Connections Boiler return Boiler flow Safety assembly connection ½ (male thread) Fig.
  • Page 41 Installation sequence Making the connections on the heating water side (cont.) Fig. 36 Thermally activated safety valve Particle filter Fig. 35 Non-return valve Pressure reducer 2 bar (0.2 MPa) 1. Install and seal the sensor well of the thermally Cold water connection activated safety valve at the back of the boiler.
  • Page 42 Installation sequence Electrical connections (cont.) Boiler with pellet hopper Fig. 37 Drive, feed Line entry Pellet hopper sensor Retaining plates Light barrier Ignition element Note Keep cables clear of rotating parts (e.g. chains, gears, rotary lock valve).
  • Page 43 Installation sequence Electrical connections (cont.) Boiler with flexible screw conveyor Fig. 38 Drive, feed Line entry Light barrier Retaining plates Sensor Ignition element Flexible screw conveyor drive Note Keep cables clear of rotating parts (e.g. chains, gears, rotary lock valve). Electrical connection When connecting external switching contacts and Please note...
  • Page 44 Installation sequence Electrical connections (cont.) Inserting cables into the control unit enclosure and 2. Route cables through cable grommets and secure applying strain relief with cable ties. Please note Note System damage may result from unsealed aper- Strip as little of the insulation as possible, close to tures in the control unit enclosure the terminals.
  • Page 45 Installation sequence Electrical connections (cont.) Actuator connection Supply system Charging Feed Suction Change- Flexible Pellet Ext. charg- scheme screw turbine over unit screw store dis- conveyor motor conveyor charge motor screw conveyor motor Setting Vacuum module with suction wand or manual change- over unit Vacuum module and discharge...
  • Page 46 Installation sequence Electrical connections (cont.) Connection of sensors and switches Supply system Charging Fuel store fill Boiler pellet Changeover Room discharge scheme level sensor hopper sensor unit limit adaptor sensor (vacuum sys- switch tem) or rotary lock valve (flex. screw convey- Setting sBÖ...
  • Page 47 Installation sequence Electrical connections (cont.) Outside temperature sensor connection Plug : Outside temperature sensor Fig. 41 Assignment Function Additional information Pt1000 — Buffer temperature sensor connection Plug : Buffer temperature sensors Fig. 42 Connection for 5 buffer temperature sensors Plug assign- Function with 5 sensors Additional infor- Sensor type...
  • Page 48 Installation sequence Electrical connections (cont.) Part of heating system Abbreviation Max. quantity Connect Heating circuit Sensor, pump, mixer motor Solar circuit Sensors, pump, mixer motor DHW heating Sensor, pump Flow limiter Valve DHW circulation pump Pump Power supply for DHW circulation pump DHW circulation pumps equipped with their own inter- nal control unit must be connected via their own sepa- rate mains connection.
  • Page 49 Installation sequence Electrical connections (cont.) Connections Connection numbers on HKK Sensor connections 301, 302, 303 302, 303 303 (collector) + 304 (lower DHW heating) Pump connections 310, 320, 330 320, 330 Mixer motor connections 311, 321, 331 DHW circulation pump connections 321, 331 Solar diverter valve (Always connect ZP to Y2)
  • Page 50 Installation sequence Electrical connections (cont.) Connections per extension kit Connections Connection numbers in extension Sensor connections HC, TWE (return temperature sen- sor) TWE (cylinder temperature sensor) Pump connection HC, TWE Mixer motor connection HC, VSB The distinctiveness and sequence of the extension kits Note must be defined via rotary selector S1 in the extension For KM-BUS connection to the PCB, see page 189.
  • Page 51 Installation sequence Electrical connections (cont.) Connection options at HKK PCB and extension kits via KM-BUS Heating circuit SOL Solar circuit TWE DHW heating (ZP) DHW circulation pump, optional Without solar To HKK PCB of the control unit To "Extension kit for heating circuit with mixer"...
  • Page 52 Installation sequence Electrical connections (cont.) With solar To HKK PCB of the control unit To "Extension kit for heating circuit with mixer" (if instal- led) via KM-BUS Connection group Rotary selector S1 setting TWE only TWE + (ZP) — — —...
  • Page 53 Installation sequence Electrical connections (cont.) Other electrical connections Make other electrical connections according to the "System examples" document and the connection and wiring diagram. See page 184. Power supply Power supply to "KSK 2.03 PCB". See "Connection Note fÖ and wiring diagram", page 189. Make earth cable "PE"...
  • Page 54 Installation sequence Fitting the casing panels Fig. 45...
  • Page 55 Installation sequence Fitting the casing panels (cont.) Fig. 46 Height adjusting screw, to set vertical position Door stop with spring; rotate stop to adjust Front adjusting screw, to set horizontal position Door stop with spring; adjust horizontal position Rear adjusting screw, to set angle of door...
  • Page 56 Installation sequence Fitting the casing panels (cont.) Fig. 47 Note Secure side panels from above with 2 self-tapping screws 3.9 x 6.5 each. Use the right-hand hole in each case.
  • Page 57 Installation sequence Fitting the casing panels (cont.) Fig. 48 Fig. 49...
  • Page 58 Installation sequence Fitting the casing panels (cont.) Note Secure panels from above with 4 self-tapping screws 3.9 x 25 each. Affixing the type plate Fig. 50 Affix the type plate to the left or right casing panel. Note Preferably affix it to the more accessible side of the boiler.

  • Page 59: Table Of Contents

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Filling the heating system....................60 • • • 2. Checking the return temperature raising facility for leaks..........61 • • • 3. Checking all connections on the heating water side for leaks •...

  • Page 60: Filling The Heating System

    Commissioning, inspection, maintenance Filling the heating system Fill water Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to appli- ance damage. ■ Flush the heating system thoroughly before filling. Only use fill water of potable water quality. ■...

  • Page 61: Checking The Return Temperature Raising Facility For Leaks

    Commissioning, inspection, maintenance Checking the return temperature raising facility for leaks Fig. 52 Checking all connections on the heating water side for leaks...

  • Page 62: Commissioning The Heating System

    Commissioning, inspection, maintenance Commissioning the heating system Commissioning with the "commissioning assistant" The commissioning assistant automatically guides you Please note through all the menus where settings have to be made. Incorrect operation at the "coding levels" may For this, "Coding level 1" is automatically active. result in damage to the appliance and the heat- ing system.
  • Page 63 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Heating water buffer cylinder: Select DHW circulation on boiler ■ ■ – Select buffer temperature sensor (set the number ■ Select solar connection of buffer temperature sensors) For solar and DHW "On the boiler": –...
  • Page 64 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Selecting the cascade and boiler number If the boiler is to be integrated in a "boiler cascade", Note press the following keys: When selecting a cascade, only the following configu- rations are available: If not installed, select: "No".
  • Page 65 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Setting "1" Setting "1" (factory setting) for pellet supply via vac- uum supply system from a pellet silo and for discharge with manual changeover unit from a pellet storage room or pellet box Fig.
  • Page 66 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Fig. 56 Setting "4" Pellet supply with suction wands from a pellet storage room, with automatic changeover unit and onward transportation via a vacuum supply system Fig. 57...
  • Page 67 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Setting "5" Pellet supply from pellet silo via flexible screw con- veyor Fig. 58 Setting "7" Pellet supply via screw conveyor system and flexible screw conveyor Fig. 59 Selecting the changeover unit/number of wands Note Only available if charging scheme "4"...
  • Page 68 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Press the following keys: To confirm. Select number of wands of the changeover unit: "2", "3", "4", "5", "6", "7" or "8" Selecting the pellet store sensor To specify whether a level sensor is present in the pel- To confirm.
  • Page 69 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Selecting the type of heating water buffer cylinder Note To change the test point for capturing the system tem- Only available if the following settings were previously perature from the top buffer temperature sensor to the selected: 2nd buffer temperature sensor, select buffer type 1: ■...
  • Page 70 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Setting buffer charging up to buffer temperature sensor Note Select buffer charging up to buffer tempera- Only available if previously: ture sensor "0", "1", "2", "3", "4" or "5". ■ Buffer temperature sensor "3", "4" or "5" To confirm.
  • Page 71 Commissioning, inspection, maintenance Commissioning the heating system (cont.) To specify the location for connection of DHW heating, To confirm. press the following keys: For "No": Not installed or DHW heating connected to a combi cylinder. For "On the boiler": Connected at internal PCB. For "On the mixer module": Connected to extension kit via KM-BUS.
  • Page 72 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Setting the solar DHW maximum temperature Only available if previously: Maximum DHW temperature "Solar on boiler" ■ To select the required max. DHW tempera- ■ "DHW" were selected. ture. ■ Or buffer type "1" was selected. To confirm.
  • Page 73 Commissioning, inspection, maintenance Commissioning the heating system (cont.) Setting the minimum system temperature Note To confirm. Only available if "Yes" for min. system temperature and no control circuits (e.g. heating circuit, DHW heat- ing, etc.) were previously selected. To set the required min. system temperature, press the following keys: To select the min.
  • Page 74 Commissioning, inspection, maintenance Commissioning the heating system (cont.) The following actuators can be switched "manually" Danger ■ "Grate Rev" Incorrectly connected actuators can cause dam- ■ "Cleaning On" age to the system. During the actuator tests, check the respective Note actuator carefully.

  • Page 75: Confirming Maintenance

    Commissioning, inspection, maintenance Commissioning the heating system (cont.) Calibrating the O probe (Lambda probe) Note The probe calibration required when replacing the Lambda probe can only be performed manually. For calibrating the Lambda probe, see "Maintenance". Filling the vacuum module Note Press the following keys: Only available if a charging scheme with vacuum mod-...

  • Page 76: Setting The Supply Times For Fuel Supply (With Vacuum System)

    Commissioning, inspection, maintenance Confirming maintenance (cont.) Calling up the "Maintenance" menu Press the following keys: For "Maintenance reset". Simultaneously for approx. 4 s. To confirm. å The "Service" menu appears. To select. For "Service functions". To confirm. To confirm. "Adopted" appears briefly on the dis- play.
  • Page 77 Commissioning, inspection, maintenance Setting the heating curves (cont.) Slope Outside temperature in °C Fig. 60 Example for outside temperature 14 °C: The heating curve is offset along the set room temper- − Underfloor heating system, slope 0.2 to 0.8 ature axis. With the heating circuit pump logic function Low temperature heating system, slope 0.8 to 1.6 enabled, the curve modifies the start and stop charac- teristics of the heating circuit pump.

  • Page 78: Starting The Heating System

    Commissioning, inspection, maintenance Setting the heating curves (cont.) Reduced room temperature Press the following keys: 14°C å For selecting the heating circuit. 3°C To confirm. B -20°C For "Reduced room temperature". To confirm. Fig. 62 Changing the reduced room temperature from 3 to 14 °C For the required value.

  • Page 79: Shutting Down The Heating System

    Commissioning, inspection, maintenance Shutting down the heating system Danger 1. Switch off the boiler by pressing "START/STOP" Contact with live or hot components can result in on the control unit. serious injuries. Before starting cleaning work, disconnect from 2. Wait until the run-on time has passed and let the the mains voltage, e.g.

  • Page 80: Emptying The Ash Box

    Commissioning, inspection, maintenance Shutting down the heating system (cont.) Activity See page After 4000 hours run After 6000 hours run Empty the ash box As required Cleaning the combustion chamber Check the grate end position and clean Check the grate limit switch Clean the flue gas fan Clean the Lambda probe Clean the flue gas collector chamber...
  • Page 81 Commissioning, inspection, maintenance Emptying the ash box (cont.) Removing the ash box Fig. 64 1. Press and hold down spring clip 5. Pull and hold pin 2. Pull open locking handle 6. Pull ash compartment in the direction of the arrow until pin locks home in the next hole.
  • Page 82 Commissioning, inspection, maintenance Emptying the ash box (cont.) Inserting the ash box Fig. 65 1. Place ash box on the platform. 5. Hook in clamping clip 2. Pull and hold pin 6. Push locking handle into closed position. 3. Push ash compartment in the direction of the arrow until pin locks home in the next hole.

  • Page 83: Cleaning The Combustion Chamber

    Commissioning, inspection, maintenance Cleaning the combustion chamber Fig. 66 1. Remove front panel screws. 3. Note Open the hinged front panel. Do not push ash from the combustion chamber bricks onto the grate. 2. Open the combustion chamber door. Clean combustion chamber with a vacuum cleaner.
  • Page 84 Commissioning, inspection, maintenance Checking the grate end position and cleaning (cont.) Fig. 67 1. Remove the casing panel. 4. Check the grate end position. 2. Open the grate maintenance cover. Note In the end position, the grate elements must be 3.
  • Page 85 Commissioning, inspection, maintenance Checking the grate end position and cleaning (cont.) Fig. 68 5. Remove the l.h. casing. 6. The gear wheel for actuating the grate limit switch must be in the switching position. Note The switching position of the limit switch is a bore in the middle gear wheel.

  • Page 86: Cleaning The Flue Gas Fan

    Commissioning, inspection, maintenance Cleaning the flue gas fan Fig. 69 Note 3. Remove the fan. Remove top casing panels. Clean the flue gas fan impeller with a soft brush and a vacuum cleaner and check for damage.

  • Page 87: Cleaning The Lambda Probe

    Commissioning, inspection, maintenance Cleaning the Lambda probe Fig. 70 Danger 2. Unhook casing panel. Hot Lambda probe may cause burns. ■ Allow the Lambda probe to cool down before 3. Remove Lambda probe , clean with a soft brush removing. and check for damage.

  • Page 88: Cleaning The Flue Gas Collector Chamber

    Commissioning, inspection, maintenance Cleaning the flue gas collector chamber Fig. 71 1. Remove top casing panel. 3. Lift off maintenance cover 2. Loosen all 4 nuts and swivel bolts with nuts to Note the side. The maintenance cover can be set down on the top casing panel.

  • Page 89: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Cleaning the heat exchanger Remove the casing. Fig. 72 1. Remove top casing panel. 3. Lift off maintenance cover 2. Loosen all 4 nuts and swivel bolts with nuts to Note the side. The maintenance cover can be set down on the top casing panel.
  • Page 90 Commissioning, inspection, maintenance Cleaning the heat exchanger (cont.) Removing the turbulators Fig. 73 1. Pull out the spring pin. 3. Remove the cover. 2. Pull out the bolts.
  • Page 91 Commissioning, inspection, maintenance Cleaning the heat exchanger (cont.) Fig. 74 4. Lift the turbulators slightly off the rocker one by one and let them slide into the pipes.
  • Page 92 Commissioning, inspection, maintenance Cleaning the heat exchanger (cont.) Fig. 75 5. Tilt the rocker upwards. 6. Pull the turbulators upwards one by one. Cleaning the heat exchanger and 2nd flue 1. Clean the heat exchanger with a cleaning brush 3. Clean the 2nd flue. and vacuum cleaner.

  • Page 93: Cleaning The Ash Chamber And Ash Removal

    Commissioning, inspection, maintenance Cleaning the ash chamber and ash removal Fig. 76 Note 3. Dismantle ash removal cover. Ash removal cover: Weight 15.5 kg 4. Clean the ash chamber with a vacuum cleaner. 1. Remove ash box. 5. If necessary, clean the screw conveyors with a 2.

  • Page 94: Cleaning The Light Barriers And Sight Glasses

    Commissioning, inspection, maintenance Cleaning the light barriers and sight glasses Fig. 77 1. Undo the cover. 5. Check the light barrier function in the "Diagnosis" menu. 2. Unscrew the top of the sight glass. Clean the sight glass. Note Operating states, actuators and sensors can be 3.

  • Page 95: Cleaning The Vacuum Module

    Commissioning, inspection, maintenance Cleaning the vacuum module Clean the vacuum module at least once per heating 1. Shut down the boiler. season, subject to the dust content of the pellets. 2. Follow the vacuum module installation and service Note instructions. Using a pellet dust extractor (accessory) can signifi- cantly reduce the maintenance effort for the entire vac- Installation and service instructions, vacuum...

  • Page 96: Cleaning The Ignition Pipe

    Commissioning, inspection, maintenance Cleaning the ignition pipe Fig. 79 1. Remove the tunnel panels. 5. Clean the ignition pipe at the air outlet using a thin brush (e.g. pipe cleaner). 2. Remove the pellet hopper casing panels. 6. Fit components in reverse order. 3.

  • Page 97: Checking The Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Checking the expansion vessel and system pressure Note 2. If the pre-charge pressure of the expansion vessel The expansion vessel can lose some of its charge is lower than the static system pressure, top up pressure over time. When the boiler heats up, the with nitrogen until the pre-charge pressure is 0.1 to pressure gauge will indicate a higher pressure of 2 or 0.2 bar (10 to 20 kPa) higher than the static system...

  • Page 98: Lubricating The Drive Unit Chains And Bearings

    Commissioning, inspection, maintenance Checking the grate limit switch and end position (cont.) Note The grate can be switched via "Actuator test" in the "Service" menu. Lubricating the drive unit chains and bearings Service the following moving parts: Note Ash removal chain set Use commercially available lubricant.

  • Page 99: Instructing The System User

    Commissioning, inspection, maintenance Instructing the system user Operating and service documents File all parts lists, operating and service instructions in the folder and hand this over to the system user. Instructing the system user The system installer should instruct the user in the Note operation of the system and hand over the cleaning The system user should provide their signature to con-...
  • Page 100 Codes Code 1 Calling up code 1 Please note For "Heating": Ù Ú Incorrect settings at "Coding level 1" may result To select "Heating circuit 1" (HC1), in damage to the appliance and the heating sys- "Heating circuit 2" (HC2), "Heating tem.
  • Page 101 Codes Code 1 (cont.) Coding in the delivered condition Possible change Buffer type Buffer type:0 When heat is drawn from the heat- Buffer type:1 When heat is drawn from the heat- ing water buffer cylinder, actual ing water buffer cylinder, actual sys- system temperature = temperature tem temperature = temperature at at buffer temperature sensor 1.
  • Page 102 Codes Code 1 (cont.) Coding in the delivered condition Possible change DHW circulation DHW circula- No DHW circulation is connected DHW circula- DHW circulation is connected to the tion:No to the boiler control unit. tion:Yes boiler control unit. Fuel store sensor Fuel store sen- No level sensor installed in the fuel Fuel store sen-...
  • Page 103 Codes Code 1 (cont.) General Coding Coding in the delivered condition Possible change Detached house/apartment building 7F:1 Detached house, same holiday 7F:0 Apartment building, holiday pro- program setting for all Heating grams can be adjusted separately. groups. Minimum temperature, top buffer sensor 91:0 No minimum temperature 91:1...
  • Page 104 Codes Code 1 (cont.) Coding in the delivered condition Possible change External demand 44:0 No external (digital) boiler demand 44:1 External (digital) boiler demand con- connected. nected. Only installed without cascade Only installed without cascade Default output 45:0 No external default output 45:1 External default output (0 - 10 V) of (0 - 10 V) of the boiler connected...
  • Page 105 Codes Code 1 (cont.) Coding in the delivered condition Possible change Discharge cycle ON 30:... Cycle, discharge 30:2 Setting range in seconds (discharge runs for ... seconds) 30:120 Discharge cycle OFF 31:... Pause, discharge 31:0 Discharge does not pause: Continu- ous operation 31:1 Setting range in seconds...
  • Page 106 Codes Code 1 (cont.) Coding in the delivered condition Possible change Buffer cylinder charging to sensor 36:3 The boiler charges the heating wa- 36:1 The boiler charges the heating water ter buffer cylinder up to buffer tem- buffer cylinder up to buffer tempera- perature sensor 3.
  • Page 107 Codes Code 1 (cont.) Coding Coding in the delivered condition Possible change Buffer charging until sensor D0:1 The additional heat generator D0:0 The heating water temperatures of charges the heating water buffer the heating water buffer cylinder cylinder up to buffer temperature temperatures are ignored.
  • Page 108 Codes Code 1 (cont.) Coding in the delivered condition Possible change Parallel operation D7:1 Parallel operation of both heat D7:0 Parallel operation of both boilers is sources is possible. not possible. Note Parallel mode only possible: If the additional heat generator has its own boiler circuit pump.
  • Page 109 Codes Code 1 (cont.) Coding in the delivered condition Possible change Summer eco function absolute A6:36 Extended economy mode disabled A6:5 Extended economy mode enabled A6:35 Adjustable value plus 1 °C: The heating circuit pump is switch- ■ ed off. The heating mixer is closed.
  • Page 110 Codes Code 1 (cont.) Coding in the delivered condition Possible change Room sensor summer eco function B5:0 Without room temperature-de- B5:1 Available if code "A0 0" is set in the > pendent heating circuit pump logic current "Heating" group. function B5:8 With room temperature-dependent heating circuit pump logic function...
  • Page 111 Codes Code 1 (cont.) Coding Coding in the delivered condition Possible change DHW differential 0C:0 The differential temperature of 0C:1 Differential temperature adjustable DHW heating is determined auto- Adjustable value in °C matically. 0C:20 Differential temperature: System temperature and DHW tempera- ture DHW return temperature 0D:10...
  • Page 112 Codes Code 1 (cont.) Coding in the delivered condition Possible change Additional function, solar 71:0 Additional function of transfer 71:0 Start time for the solar additional pump disabled. function. Code available if the output of the 71:23 Solar additional function: Signal for HKK PCB is available.
  • Page 113 Codes Code 2 Calling up code 2 Please note To confirm Incorrect settings at "Coding level 2" may result in damage to the appliance and the heating sys- For the required group tem. Follow instructions. To confirm Note For "Heating": To select "Heating cir- Ù...
  • Page 114 Codes Code 2 (cont.) Coding in the delivered condition Possible change ≙ 90:0 Adjusted outside temperature current outside temperature Outside temperature offset 92:0 No outside temperature correction 92:- 10 Outside temperature correction Adjustable value in °C 92:10 Boiler Coding Coding in the delivered condition Possible change Flue gas residual O2 partial load correction 0D:...
  • Page 115 Codes Code 2 (cont.) Coding in the delivered condition Possible change Boiler pump maximum speed 1D:... Boiler circuit pump speed 1D:15 Adjustable value in % Code only enabled for boiler circuit pumps with PWM signal. 1D:100 Flue gas temperature minimum 3F:...
  • Page 116 Codes Code 2 (cont.) Coding in the delivered condition Possible change Primary air damper partial load 83:... Do not change. 83:... 83:... Primary air damper boiler start 84:... Do not change. 84:... 84:... Secondary air damper minimum 87:... Do not change. 87:...
  • Page 117 Codes Code 2 (cont.) Coding in the delivered condition Possible change Fuel consumption 22:... Setting for fuel consumption 22:... Setting range in kg/h Amount of fuel delivered by the feed 22:... screw conveyor in one hour Changeover unit 64:... Setting indicating the number of 64:2 Setting range: Two to eight wands wands of the changeover unit.
  • Page 118 Codes Code 2 (cont.) Coding in the delivered condition Possible change Frost protection temperature A3:2 Outside temperature below 1 °C: A3:-9 Frost protection function "On"/"Off" Frost protection function "On" See the following table Outside temperature above 3 °C: A3:15 Frost protection function "Off" Please note If the frost protection temperature is set to less than 1 °C outside temperature, uninsulated...
  • Page 119 Codes Code 2 (cont.) Coding in the delivered condition Possible change Room sensor offset E2:50 Available if code "A0:1", "A0:2" or E2:0 Correction - 5 K to display correction "A0:3", "Heating" group, is set. - 0.1 K No correction of actual room tem- E2:49 perature E2:51...
  • Page 120 Diagnosis and service scans Service functions The following service functions can be selected: Service function See page Function "Diagnosis" Checking operating states, actuators and sensors "Actuator test" Checking the actuators "Code 1" Configuring the system "Code 2" Configuring the system "Fault history"...
  • Page 121 Diagnosis and service scans Checking operating states, actuators and sensors Operating states, actuators and sensors can be Note checked in the following menus: Check temperature values or states of all inputs for ■ Under "Information" "function and logic". Submenu in the extended "Standard menu". ■...
  • Page 122 Diagnosis and service scans Checking the outputs (actuators) (cont.) The following actuators can be switched "manually" Note "Additional boiler" Depending on boiler size and settings, other actuators "Additional boiler On" ■ may be available. "Heating circuit 1" "General" ■ "Pump On" ■...
  • Page 123 Diagnosis and service scans Filling the vacuum module Installation and service instructions, vacuum module Calls up the "Fill vacuum module" menu Simultaneously for approx. 4 seconds To confirm å The "Service" menu appears. For "Yes" For "Service functions" To confirm To confirm Until the default display is shown.
  • Page 124 Diagnosis and service scans Checking the changeover unit This function is for testing or manually switching the changeover unit. Caution Incorrect operation of the changeover unit can cause a blockage in the vacuum system. When the "Suction" function is active, observe the fill level of the pellet hopper.
  • Page 125 Diagnosis and service scans Checking the changeover unit (cont.) Manual operation of changeover unit Positioning the changeover unit A "set position for the changeover unit" can be This set position is automatically approached by the selected by pressing changeover unit. This changes the "actual position of the changeover unit".
  • Page 126 Diagnosis and service scans Loading the standard setting (cont.) For "Standard setting" For "Yes" To confirm To confirm To select Until the default display is shown. ä To confirm...
  • Page 127 Fault rectification Fault display Faults are signalled on the display by the "Fault" mes- A central fault message facility connected to plug gÖ sage and by the red fault indicator flashing. switched on. Checking and acknowledging faults Note To "Acknowledge" all fault messages If an acknowledged fault is not remedied, the fault message will be redisplayed the following day at For "Yes"...
  • Page 128 Fault rectification Fault display (cont.) Deleting saved fault codes from the fault memory Press the following keys: To "Delete". Simultaneously for approx. 4 seconds. To confirm. å The "Service" menu appears. For "Yes". For "Fault history". To confirm. To confirm. Until the default display is shown.
  • Page 129 Fault rectification Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control unit set to 0 °C out- Short circuit, outside tem- Check outside temperature sensor. side temperature perature sensor No DHW heating Short circuit, top buffer Check top buffer temperature sen- temperature sensor sor.
  • Page 130 Fault rectification Fault codes (cont.) Fault code dis- System characteristics Cause Measures played No room influence at remote Lead break to remote con- Check connection to remote con- control with room tempera- trol with room temperature trol room temperature capture. ture capture 3 (KM BUS) capture 3 (KM BUS) No reheating suppression via...
  • Page 131 Fault rectification Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner blocked Return temperature not Check return temperature sensor. reached during operation. Check mixer motor of return tem- perature raising facility. Installation and service in- structions, return tempera- ture raising facility Burner blocked Oxygen content in flue...
  • Page 132 Fault rectification Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner blocked Fault, material shortage Check fuel store fill level ■ For 8 and 12 kW – manual ■ charging: Check the fill level of the day hopper. For 18 to 48 kW –...
  • Page 133 ■ Burner blocked Proximity switch in pellet Clean proximity switch. hopper is constantly con- taminated. Boiler output deviating Program memory error. Notify heating contractor. Check boiler type in the control unit. Fault message only for Vitoligno 300-C 18-48 kW boilers.
  • Page 134 Maintenance Fuses Installation position, see page 185. ■ 10 A (slow) ■ 5 A (slow) ■ 250V 50/60 Hz ■ 250V 50/60 Hz KSK PCB power cable HKK PCB power cable ■ ■ ■ 5 A (slow) ■ 250V 50/60 Hz ■...
  • Page 135 Maintenance High limit safety cut-out (cont.) 1. Move cover on the programming unit to the right. 2. Press green button of the high limit safety cut- out. A quiet "click" will be audible. The high limit safety cut-out has been reset. 3.
  • Page 136 Maintenance Sensors (cont.) Further sensors 1.20 1.15 1.10 1.05 1.00 0.95 0.90 0.85 Temperature in °C Fig. 83 1. Pull out corresponding plug. 3. Compare the result with the actual temperature (for scanning, see chapter "Diagnosis"). 2. Check the sensor resistance at the plug. In the case of severe deviation, check sensor installation and replace the sensor if required.
  • Page 137 Maintenance Lambda probe (cont.) 7. Press to select "Calibrate O2 probe". 9. Wear safety gloves. Confirm with 8. Press to select "Yes". Confirm with Note Probe is calibrated correctly if 21 % O is dis- played. Connection The Lambda probe is connected at slot .
  • Page 138 Maintenance Extension kit for heating circuit with mixer (cont.) Changing the rotational direction of the mixer motor (if required) Danger An electric shock can be life threatening. Before opening the boiler, disconnect it from the mains voltage, e.g. at the fuse or mains isolator. 1.
  • Page 139 Parts lists Overview of assemblies The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) Fig. 87 Type plate Return temperature raising facility assembly Thermal insulation assembly...
  • Page 140 Parts lists Thermal insulation assembly 0016 0011 0023 0012 0024 0022 0007 0005 0008 0020 0017 0013 0019 0034 0018 0009 0021 0034 0020 0035 0017 0010 0003 0019 0017 0025 0001 0017 0025 0035 0018 0002 0006 0004 0015 0036 0030 0029...
  • Page 141 Parts lists Thermal insulation assembly (cont.) Pos. Part 0001 Casing panel, door 0002 Casing panel, top right 0003 Retainer for programming unit 0004 Casing panel, bottom front 0005 Casing panel, left 0006 Casing panel, right 0007 Casing panel, top back 0008 Casing panel, top centre back 0009...
  • Page 142 Parts lists Thermal insulation assembly (cont.)
  • Page 143 Parts lists Boiler overview 0002 0003 0005 0004 0001 Fig. 89 0001 Combustion chamber assembly 0004 Ash removal assembly 0002 Ignition and drive systems assembly 0005 Cleaning assembly 0003 Doors assembly...
  • Page 144 Parts lists Combustion chamber assembly 0005 0004 0002 0001 0003 Fig. 90...
  • Page 145 Parts lists Combustion chamber assembly (cont.) Pos. Part 0001 Grate (wearing part) 0002 Grate base 0003 Combustion chamber bricks, set 1 (wearing part) 0004 Combustion chamber bricks, set 2 (wearing part) 0005 Brick insert (wearing part)
  • Page 146 Parts lists Ignition and drive systems assembly 0014 0013 0017 0011 0010 0015 0012 0015 0010 0016 0009 0010 0016 0017 0008 0005 0005 0003 0007 0002 0002 0003 0018 0002 0002 0018 Fig. 91...
  • Page 147 Parts lists Ignition and drive systems assembly (cont.) Pos. Part 0002 Flanged bush (wearing part) 0003 Drive shaft for gear wheel 0005 Gear wheel, centre (wearing part) 0007 Synchronous motor 0008 Gear wheel drive shaft (wearing part) 0009 Air damper with motor 0010 Stepper motor 0011...
  • Page 148 Parts lists Doors assembly 0010 0011 0012 0011 0013 0004 0005 0002 0006 0003 0004 0005 0007 0006 0007 0008 0009 0008 0003 0001 0009 0004 Fig. 92...
  • Page 149 Parts lists Doors assembly (cont.) Pos. Part 0001 Maintenance cover, grate 0002 Combustion chamber door 0003 Gasket 25 x 25 (wearing part) 0004 Insulation block holder (wearing part) 0005 Insulation block 1 (wearing part) 0006 Insulation block 2 0007 Insulation block 3 0008 Insulation block 4 0009...
  • Page 150 Parts lists Ash removal assembly 0011 0015 0012 0010 0002 0014 0013 0005 0009 0010 0003 0008 0007 0002 0006 0004 0003 0001 0004 0003 0004 Fig. 93...
  • Page 151 Parts lists Ash removal assembly (cont.) Pos. Part 0001 Connection, ash box 0002 Profiled seal, ash removal (wearing part) 0003 Gasket 16 x 12 (wearing part) 0004 Gasket, connection piece, ash box (wearing part) 0005 Ash trough, grate 0006 Ash trough, heat exchanger 0007 Mounting plate, ash removal 0008...
  • Page 152 Parts lists Cleaning assembly 0017 0006 0007 0008 0014 0009 0011 0003 0010 0016 0013 0015 0015 0004 0003 0002 0005 0003 0012 Fig. 94...
  • Page 153 Parts lists Cleaning assembly (cont.) Pos. Part 0002 Connection pipe, eccentric 0003 Flanged bush 20 x 17 (wearing part) 0004 Tensioning shaft 0005 Tensioning shaft, short 0006 Gimbal fixing kit 0007 Gimbal shaft 0008 Studs 0009 Spring pin 3 0010 Compression spring (wearing part) 0011 Cleaning mechanism...
  • Page 154 Parts lists Ash box assembly 0001 0005 0002 0003 0004 0003 0004 0004 0004 0006 0006 0007 Fig. 95...
  • Page 155 Parts lists Ash box assembly (cont.) Pos. Part 0001 Extendible handle 0002 Gasket 12 x 12 (wearing part) 0003 Clamping clip 0004 Toggle fastener 0005 Handle 0006 Castor set 0007 Plastic strip...
  • Page 156 Parts lists Control unit assembly 0020 0048 0050 0030 0023 0022 0032 0047 0049 0031 0025 0033 0044 0043 0027 0045 0024 0046 0052 0028 0036 0026 0021 0051 0035 0034 0029 0041 0042 0016 0018 0019 0038 0040 0037 0039 0008 0010...
  • Page 157 Parts lists Control unit assembly (cont.) Pos. Part 0001 Connecting cable, heating element (wearing part) 0002 Connecting cable, boiler cleaning 0003 Connecting cable, boiler circuit pump 0004 Connecting cable, boiler valve 0005 Connecting cable, primary stepper motor 0006 Connecting cable, secondary stepper motor 0007 Connecting cable, ash removal motor 0008...
  • Page 158 Parts lists Control unit assembly (cont.) Pos. Part 0047 BLS plug-in PCB for wideband probe 0048 Main emergency stop switch 0049 Programming unit 0050 Timer charge motor 0051 Jumper set, PCB 0052 Earth wire...
  • Page 159 Parts lists Control unit assembly (cont.)
  • Page 160 Parts lists Return temperature raising facility assembly 0007 0008 0004 0005 0002 0003 0006 0009 0002 Fig. 97...
  • Page 161 Parts lists Return temperature raising facility assembly (cont.) Pos. Part 0002 Ball valve 1 1/2" 0003 Fitting 1 1/2" 0004 3-way mixing valve 0005 Actuator 0006 Circulation pump 0007 Gasket A 30 x 44 x 2 0008 Gasket set 2" (2 pce) 0009 Corrugated pipe...
  • Page 162 Parts lists Return temperature raising facility assembly (cont.)
  • Page 163 Parts lists Charging overview 0001 0002 0003 Fig. 98 0001 Flexible screw conveyor 0002 Pellet hopper 0003 Vacuum module Installation and service instructions, vacuum module...
  • Page 164 Parts lists Flexible screw conveyor assembly 0012 0020 0003 0007 0006 0011 0002 0004 0008 0015 0005 0009 0015 0019 0010 0014 0001 0013 0014 0016 0016 0017 0018 0018 0013 0017 Fig. 99...
  • Page 165 Parts lists Flexible screw conveyor assembly (cont.) Pos. Part 0001 Rotary adjuster 0002 Rotary unit 0003 90 W geared motor 0004 Flexible spiral 3 m 0005 Flexible spiral 4 m 0006 Motor shaft 0007 Washers, rotary unit 0008 Hose 3 m 0009 Hose 4 m 0010...
  • Page 166 Parts lists Pellet hopper assembly 0014 0013 0018 0012 0017 0017 0011 0010 0015 0008 0007 0009 0004 0003 0016 0001 0005 0006 0002 Fig. 100...
  • Page 167 Parts lists Pellet hopper assembly (cont.) Pos. Part 0001 Thermal casing, r.h. 0002 Thermal casing, l.h. 0003 Casing, r.h. 0004 Casing, l.h. 0005 Casing installation components 0006 Adjustable foot 0007 Casing, flexible screw conveyor, r.h. 0008 Casing, flexible screw conveyor, l.h. 0009 Neoprene sealing tape (wearing part) 0010...
  • Page 168 Parts lists Vacuum module assembly 0005 0006 0001 0005 0004 0003 0002 0007 Fig. 101...
  • Page 169 Parts lists Vacuum module assembly (cont.) Pos. Part 0001 Vacuum module 0002 Pellet hose bracket 0003 Connection set, vacuum module 0004 Mounting panel, vacuum module 0005 Power cable, suction turbine 0006 2-pole earth cable 0007 Installation and service instructions, vacuum module Installation and service instructions, vacuum module...
  • Page 170 Parts lists Feed assembly 0008 0011 0006 0005 0007 0013 0008 0004 0006 0005 0013 0018 0010 0017 0003 0012 0009 0004 0010 0002 0014 0001 0016 Fig. 102...
  • Page 171 Parts lists Feed assembly (cont.) Pos. Part 0001 Offset geared motor 0002 Gasket (wearing part) 0003 Sprocket set, feed (wearing part) 0004 Locking pin set (wearing part) 0005 Sprocket shaft (wearing part) 0006 Deep groove ball bearing 25 x 47 x 12 (wearing part) 0007 Rotary lock valve 0008...
  • Page 172 Parts lists Miscellaneous assembly 0007 0005 0003 0001 0006 0008 0009 0002 0004 Fig. 103...
  • Page 173 Parts lists Miscellaneous assembly (cont.) Pos. Part 0001 Scraper 0002 Wire brush (wearing part) 0003 0004 Spring brush (wearing part) 0005 Touch-up spray paint, Vitosilver 0006 Touch-up paint stick, Vitosilver 0007 Spray paint, anthracite 0008 Installation and service instructions 0009 Operating instructions 0010 Socket spanner, Lambda probe...
  • Page 174 Function description Display and control elements Display Buffer drawing Boiler Buffer Heating Select with Fig. 104 Display of operating phase Cursor keys Dialogue line Scroll through the menu or adjust values. Confirm selection or save the setting made. Back key Return to the previous step in the menu or cancel Calling up help text for the selected menu item a setting that has been started.
  • Page 175 Function description Display and control elements (cont.) Function of appliance mains isolator The appliance mains isolator is used to isolate the con- trol unit from the power supply. It does not turn off the mains power supply. After switching off, there are still live components inside the control unit enclosure.
  • Page 176 Function description Control functions (cont.) Heating curve of the heating water buffer cylinder Time program You can set these charging times by adjusting the time Heating curve Buffer program for the heating water buffer cylinder. During the set time phases, the charging level of the 100 °C heating water buffer cylinder has an effect on the boiler operation.
  • Page 177 Function description Control functions (cont.) Functions Control mode Reheating suppression with solar circuit The boiler combustion output is reduced if the "Actual buffer temperature " "Set buffer temperature " . ≥ If a solar circuit is installed, reheating suppression of the heating water buffer cylinder can be selected.
  • Page 178 Function description Control functions (cont.) The heating curve characteristics determine the set flow temperature subject to outside temperature. The control unit regulates in line with an average outside temperature. This is made up of the actual and the adjusted outside temperature. Example using the settings in the delivered condition Outside temperature in °C Fig.
  • Page 179 Function description Control functions (cont.) Extended economy mode The mixer has been closed for 12 min. (mixer econ- ■ omy function, coding address "A7"). The heating circuit pump is switched off and the set ■ The actual room temperature exceeds the value flow temperature is set to 0 °C if one of the following selected via coding address "B5".
  • Page 180 Function description Control functions (cont.) Cylinder temperature control Cylinder temperature control is a constant tempera- Set DHW temperature ■ ture control. It operates by starting and stopping the circulation pump for cylinder heating. The set DHW temperature can be adjusted between The switching differential is 10 K.
  • Page 181 Function description Control functions (cont.) Screed drying function This function enables screeds to be dried. For this, Various temperature profiles are adjustable via coding observe the screed manufacturer's instructions. address "F1". When the screed drying function is enabled, the heat- The function continues after a power failure or after the ing circuit pump is switched on and the flow tempera- control unit has been switched off.
  • Page 182 Function description Control functions (cont.) Temperature profile 5, code "F1:5" ϑ/°C Fig. 113 Temperature profile 6, code "F1:6" ϑ/°C Fig. 114 Vacuum supply system A vacuum system transports the pellets from the con- nector of the room discharge or pellet silo into the pel- let hopper on the boiler.
  • Page 183 Function description Combustion flow chart Fig. 115 A' Burner start initiation ra1 Flushing speed Flushing phase ra2 Ignition speed Combustion chamber filling e1 Charge time entry Ignition Ignition on 2nd ignition phase Air damper calibration Control mode Air damper flushing position Burnout phase Air damper ignition position G Boiler cleaning...
  • Page 184 Connection and wiring diagram Position of PCBs Danger Touching live components can result in serious injuries. Isolate the system from the power supply (e.g. by removing the separate fuse or by means of a mains isolator) and check that it is no longer live.
  • Page 185 Connection and wiring diagram Overview of PCBs ZPK 2.02 HKK 2.01 KSK 2.03 IP (+/-) VS (+) Fig. 117 PCB layout, date: 04/2016 Power supply unit, boiler control unit ZPK 2.02 PCB HKK 2.01 PCB KSK 2.03 PCB Programming unit BLS 1.01 PCB Battery Fuse F10...
  • Page 186 Connection and wiring diagram ZPK 2.02 PCB Fig. 118 Limit switch, ash removal Reserve Safety limit switch, silo door Performance feedback Fill level, fuel store Limit switch, finned grate Pellet sensor (hopper) Jumper for output parameter settings , factory s;Ö Limit switch, pellet changeover unit setting: Open sBÖ...
  • Page 187 Connection and wiring diagram ZPK 2.02 PCB (cont.) Danger Touching live components can result in serious injuries. Isolate the system from the power supply (e.g. by removing the separate fuse or by means of a mains isolator) and check that it is no longer live.
  • Page 188 Connection and wiring diagram HKK 2.01 PCB Fig. 120 Flow temperature sensor, heating circuit 1 Flow temperature sensor for heating circuit 2 or cylinder temperature sensor Fig. 121 Cylinder temperature sensor, collector tempera- ture sensor or flow temperature sensor for Connection to ZPK 2.02 and KSK 2.03 PCBs heating circuit 3 s-Ö...
  • Page 189 Connect DHW circulation pumps with standalone func- ∼ supply. the system version. tions directly to the 230 V Mains connection via the Viessmann control unit or System-specific slot assignment: Viessmann control unit accessories is not permissible. "System examples" KSK 2.03 PCB Fig.
  • Page 190 Connection and wiring diagram KSK 2.03 PCB (cont.) Danger Touching live components can result in serious injuries. Do not remove the plug in slot fÖ Do not connect any devices at slot fÖ Fig. 123 Boiler circuit pump High limit safety cut-out and ON/OFF switch aBÖ...
  • Page 191 Connection and wiring diagram List of connected cables (cont.) Plug Description Cable type Number Cable cross- Length of cores section in m Standard Alternative- in mm Boiler valve H05VV F H05RN F 0.75 Lambda probe H05VV F H05RN F 0.75 Ignition element H05VV F H05RN F...
  • Page 192 Connection and wiring diagram List of connected cables (cont.) Plug Description Cable type Number Cable cross- Length of cores section in m Standard Alternative- in mm Sensor H03VV F H03RN F 0.75 – Sensor H03VV F H03RN F 0.75 – Sensor H03VV F H03RN F...
  • Page 193 Commissioning/service reports Commissioning/service reports Commissioning Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date:...
  • Page 194 Specification Specification Rated heating output range Q Minimum heating output Q Flow temperature °C Permissible ■ °C Maximum ■ °C Minimum ■ Minimum return temperature °C Boiler pressure drop on the water side Residual head 2.11 6.47 Boiler water capacity Permiss.
  • Page 195 Specification Specification (cont.) Rated heating output range Q Required draught At rated heating output ■ mbar 0.05 At partial load ■ mbar 0.03 Max. permiss. draught mbar 0.15 Flue gas Average temperature (gross) At rated heating output ■ º At partial load (30 % of upper rated heating output) º...
  • Page 196 Decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.
  • Page 197 Certificates Declaration of conformity Vitoligno 300-C, type 60 - 70 kW We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, declare as sole responsible body that the named product complies with the provisions of the following directives and regulations: 2006/95/EC...
  • Page 198 Keyword index Keyword index Diagnosis menu............121 Actuator test............. 122 Diaphragm expansion vessel........97 Appliance fuses, checking........134 Display..............174 Appliance mains isolator.......... 175 Display elements............174 Assemblies – Parts lists...............139 Economy mode............178 Ecotronic Battery..............134 – Connection options (overview)........51 Boiler room Electrical connections..........
  • Page 199 Keyword index Keyword index (cont.) Ignition element............138 Parts lists Information menu............. 121 – Overview of assemblies........139 Installation room PCBs – Requirements............9 – HKK 2.01...............188 – Requirements installation room floor......9 – KSK 2.03............... 189 – Overview............... 185 – Position..............184 Lambda probe............
  • Page 200 (cont.) Vacuum supply system..........182 Wall clearances............17 Applicability Serial no. 7357457 7357458 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...

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