Viessmann VH3, Installation And Service Instructions For Contractors

Page 1: ...Installation and service instructions for contractors Viesmann Vitoligno 300 H Type VH3 50 to 60 kW Boiler for woodchips and pellets VITOLIGNO 300 H 5679249 GB 10 2019 Please keep safe ...

Page 2: ... to be observed National installation regulations Statutory regulations for the prevention of accidents Statutory regulations for environmental protection Codes of practice of the relevant trade associations Relevant country specific safety regu lations Safety instructions for working on the system Working on the system Wear suitable personal protective equip ment when carrying out any work Danger...

Page 3: ...e not been tested together with the system can compromise its func tion Installing non authorised com ponents and making non approved modifications or conversions can compromise safety and may invalid ate our warranty For replacements use only original spare parts supplied or approved by Viessmann Safety instructions for operating the system If you smell flue gas Danger Flue gas can lead to life t...

Page 4: ...pply of combus tion air can cause life threatening poisoning from carbon monoxide in the flue gas Ensure the flue system is in good working order Vents for supplying combustion air must be non seala ble Extractors Operating appliances that extract air to the outside extractor hoods extractors air conditioning units etc can create negative pressure If the boiler is oper ated at the same time this c...

Page 5: ...on the heating water side 24 Overview of connections 25 Installing the return temperature raising facility 25 Making the safety connections 25 Connecting the thermally activated safety valve 26 System version 28 Electrical connections 29 Routing cables 29 Electrical connection 30 Overview of electrical connections 31 Power supply 39 Regulations 39 Connecting the emergency stop mains isolator provi...

Page 6: ...rd setting 117 Calling up the Standard setting menu 117 7 Troubleshooting Fault indicator 118 Checking and acknowledging faults 118 Calling up acknowledged fault messages 118 Calling up fault codes from the fault memory fault history 118 Deleting saved fault codes from the fault memory 118 Fault displays in plain text 119 Fault codes 119 8 Maintenance Fuses 126 Appliance fuse protection to EN 6012...

Page 7: ... wiring dia gram Position of the PCBs 142 Overview of the PCBs 143 PCB ZPK 2 03 143 PCB HKK 2 01 146 PCB KSK 2 03 148 Electrical installation 150 Requirements 150 Electrical cables leads 151 11 Commissioning service reports 153 12 Specification 154 13 Decommissioning and dis posal Final decommissioning and disposal 158 14 Certificates Declaration of conformity 159 15 Keyword index 160 Index Index ...

Page 8: ...ion and identified as follows Symbol Meaning Steps required during commissioning Not required during commissioning Steps required during inspection Not required during inspection Steps required during maintenance Not required during maintenance Intended use The appliance is only intended to be installed and operated in sealed unvented heating systems that comply with EN 12828 with due attention pa...

Page 9: ...f a mains isolator and check that it is no longer live Safeguard the system against reconnection Danger There is a risk of fire and burns due to hot com ponents and cinders Switch off the boiler and let it cool down Carry out maintenance and cleaning work only on central heating boilers that have cooled down Allow hot components to cool down before removing Wear suitable personal protective equipm...

Page 10: ...oom floor requirements The boiler must be positioned on a non combustible temperature resistant substrate Requirements regarding the load bearing capacity of the boiler room floor See the technical guide for the boiler Handling Danger Risk of injury due to the boiler tilting or falling Lift at the transport lug using flexible sling gear or shackles Transport with pallet truck forklift truck Please...

Page 11: ...11 1 2 4x Fig 1 1 Remove thermal insulation from under the boiler 2 Undo the transport brackets Preparing for installation Handling cont 5679249 Installation ...

Page 12: ...nstallation location with pallet truck or forklift truck 5 Remove and retain the bag containing the boiler type plate from the combustion chamber door Note The type plate is later affixed to the left hand or right hand casing panel 6 Remove the cleaning set from the boiler and keep it safe Preparing for installation Handling cont 5679249 Installation ...

Page 13: ...f the width of the access is less than 900 mm first remove certain components as described in chapter Removing components for access 900 mm below Removing components for access 900 mm 1 2 Fig 5 1 Remove pump head 2 Pull out plug Preparing for installation Handling cont 5679249 Installation ...

Page 14: ...d 4 Use a dismantling aid e g two armed puller to remove the motor with torque support Note Motor dimensions Width 100 mm Depth 84 mm incl flange plate Shaft diameter 20 mm 5 Lift out the feather key 6 Remove chain tensioner 7 Remove chain by opening the master link Preparing for installation Handling cont 5679249 Installation ...

Page 15: ...he boiler in its final position refit the com ponents in reverse order Siting requirements The specified wall clearances are required for instal lation and maintenance work The space above the boiler must remain free for maintenance work Required room height At least 2 1 m Preparing for installation Handling cont 5679249 Installation ...

Page 16: ...ng for an uneven floor 1 2 4x Fig 8 Note Any unevenness of the boiler room floor can be com pensated via the 4 adjusting screws on the boiler Preparing for installation Siting requirements cont 5679249 Installation ...

Page 17: ...A Fig 9 Note Keep area A behind the boiler clear for installation and maintenance work Rated heating output kW 50 60 Wall clearances a mm 700 700 b mm 400 400 c mm 100 100 d mm 800 800 Preparing for installation Siting requirements cont 5679249 Installation ...

Page 18: ...h limit safety cut out STB can cause the heating system to fail permanently Do not bend capillaries and observe the mini mum permissible radius 5 mm when bending them If the capillaries are bent or damaged the high limit safety cut out must be replaced 1 Fit the programming unit Note Unhook the securing straps of the programming unit and remove them 2 Plug the ribbon cable of the programming unit ...

Page 19: ...19 2 1 Fig 11 1 Hook platform into place 2 Pivot platform downwards Installation sequence Fitting the platform 5679249 Installation ...

Page 20: ...can damage the boiler room floor Insert thermal insulation Slide the thermal insulation under the boiler as far as it will go Note Floor pan with thermal insulation Weight 11 kg Installation sequence Fitting the bottom thermal insulation 5679249 Installation ...

Page 21: ... and hold pin D 3 Push ash partition E in the direction of the arrow until pin D locks home in the next hole 4 Push ash box towards the boiler 5 Hook in clamping clip C Note The boiler can only be started with the ash box fitted Fitting the feed and burn back protection Feed installation and service instructions Installation sequence Mounting the ash box 5679249 Installation ...

Page 22: ...22 A Fig 14 1 Insert the ignition unit into the pipe 2 Secure locking ring A Installation sequence Fitting the ignition unit 5679249 Installation ...

Page 23: ...ning from flue gas and carbon monoxide Ensure the flue system is in good working order Apertures for combustion air supply must be non closable The system may only be commissioned once the fol lowing conditions are guaranteed Unrestricted flow in the flue gas routes Flue pipes are routed so that all casing panels are accessible and can be removed for maintenance Flue systems are designed to be gas...

Page 24: ...ermal insulation C Cleaning aperture with test connector for checking flue gas temperature and emissions Test connector calming stretch Upstream of the test connector Total 3 x 7 of the flue pipe To the last pipe bend Min 2 x 7 To the flue outlet Min 1 x 7 Downstream of the test connector At least 1 to 2 x 7 of the flue pipe D Flexible flue pipe inlet E Possible installation location for the draug...

Page 25: ... used install it now Installation instructions for return temperature raising facility Making the safety connections Safety equipment block installation instructions Install the safety lines Permiss operating pres sure 3 bar 0 3 MPa Test pressure 4 5 bar 0 45 MPa Note The connection between boiler and expansion vessel must not be interrupted by shut off devices Information regarding the safety val...

Page 26: ...nnecting the thermally activated safety valve The valve of the thermally activated safety device is mounted on the back of the boiler Connections to the boiler A Safety heat exchanger Cold water inlet R 1 2 B Safety heat exchanger DHW drain pipe R 1 2 Danger Incorrect installation of thermally activated safety equipment can lead to injury and material damage Any contamination of the system must be...

Page 27: ... 19 A Thermally activated safety valve B Burn back protection valve for feed system at cold water connection 2 Connect the safety heat exchanger Install components A to E in the cold water inlet Connect the burn back protection device for the feed via valve B 3 Insert the sensor of the thermally activated safety valve as far as it will go into the sensor well and secure Installation sequence Makin...

Page 28: ...h one or more heating circuits with mixer heating water buffer cylinder and DHW heat ing 2 302 2 320 2 320 2 321 2 301 2 310 2 311 2 303 2 331 2 2 1 2 182 2 29 2 29B 2 330 2 9 1 2 9 3 2 9 2 Fig 20 Note This scheme is a general example without shut off valves or safety equipment This does not replace the need for on site engineering Installation sequence Making the connections on the heating water ...

Page 29: ...he pro gramming unit Place the casing panel with the programming unit on the boiler 2 Open the cover of the control unit enclosure 3 Route the internal and external cables as follows Route the cables in the cable guide The rear cable entry is only available after the casing has been fitted Cables must be fastened to the retaining plates with cable ties Route 400 230 V cables and extra low voltage ...

Page 30: ...th and 2 0 mm insulation thickness towards live components For all components provided on site ensure safe elec trical separation in accordance with EN 60335 and IEC 60065 This includes PCs and laptops Please note Electronic assemblies can be damaged by elec trostatic discharge Prior to commencing any work touch earthed objects such as heating or water pipes to dis charge static loads Inserting ca...

Page 31: ...es Overview of electrical connections Part of heating system Chapter Page Actuators sensors and switches Connections for fuel supply system to ZPK PCB of the control unit Commissioning 49 Outside temperature sensor Overview of electrical connections 31 Buffer temperature sensors Overview of electrical connections 32 Heating circuits solar circuit DHW etc Connection options at the HKK PCB and exten...

Page 32: ... note Incorrect connections may cause malfunctions Observe the instructions provided in this chap ter Part of heating system Abbreviation Max quantity Connect Heating circuit HC 4 Sensor pump mixer motor Solar circuit SOL 1 Sensors pump mixer motor DHW heater TWE 1 Sensor pump DHW circulation pump ZP 1 Pump Circulation pump for transferring heat from the DHW cylinder Additional solar function UP 1...

Page 33: ...TWE SOL or internal electrostatic precipitator The connections of a connection group belong together The appliances for a specific heating circuit must be connected to the connections of a group For a detailed overview of connection options see ZPK 2 03 PCB in chapter Connection and wiring dia gram Installation sequence Electrical connections cont 5679249 Installation ...

Page 34: ...tions C Circulation pump connections C DHW circulation pump connections C Solar diverter valve C Power supply to electrostatic precipitator C HK 311 321 331 UP 321 331 Always connect UP to Y1 ZP 321 331 Always connect ZP to Y2 SOL 331 Power supply Electrostatic precipita tor optional 331 Extension kits KM BUS Max 3 extension kits can be connected to the boiler control unit Each extension kit must ...

Page 35: ...rn temperature sen sor 2 TWE cylinder temperature sensor 17 Pump connection HC TWE 20 Mixer motor connection HC VSB 52 The distinctiveness and sequence of the extension kits must be defined via rotary selector S1 in the extension kit Extension kit S1 rotary selector position E1 1 2 3 4 5 6 1 0 9 8 7 E2 3 2 3 4 5 6 1 0 9 8 7 E3 5 2 3 4 5 6 1 0 9 8 7 Note For KM BUS connection to the PCB see page 14...

Page 36: ...ately downstream of HC without a gap Exception If only the TWE is connected to the HKK connect it at A2 TWE at E1 E2 or E3 Note Connect TWE downstream of HC without a gap ZP UP only at A2 or A3 VSB possible in addition to TWE ZP UP possible in addition to TWE SOL only at A3 Note It is not possible to connect solar control module type SM1 Solar circuit at the boiler only possible if TWE or buf fer ...

Page 37: ...C1 HC2 HC1 ZP HC2 3 heating circuits with mixer HC1 HC2 HC3 ZP HC1 HC2 HC3 HC1 HC2 ZP HC3 HC1 ZP HC2 HC3 4 heating circuits with mixer HC1 HC2 HC3 HC4 HC1 ZP HC2 HC3 HC4 HC1 HC2 ZP HC3 HC4 1 heating circuit with mixer and TWE HC1 TWE ZP HC1 ZP TWE TWE ZP HC1 ZP HC1 TWE 2 heating circuits with mixer and TWE HC1 HC2 TWE ZP HC1 HC2 ZP TWE HC1 ZP HC2 TWE ZP HC1 HC2 TWE HC1 TWE ZP HC2 TWE ZP HC1 HC2 3 ...

Page 38: ...TWE UP ZP SOL HC1 HC2 3 heating circuits with mixer solar and TWE HC1 HC2 SOL HC3 TWE HC1 UP ZP SOL HC2 HC3 TWE HC1 TWE UP ZP SOL HC2 HC3 TWE UP ZP SOL HC1 HC2 HC3 4 heating circuits with mixer solar and TWE HC1 HC2 SOL HC3 HC4 TWE HC1 TWE UP ZP SOL HC2 HC3 HC4 Solar and TWE on ly no heat demand TWE UP ZP SOL UP ZP SOL TWE Vitosolic 100 or Vitosolic 200 at KM BUS If a solar circuit is connected to...

Page 39: ...e with installation requirements Recommended power cable For the position of mains connection sYÖ see ZPK 2 03 PCB in chapter Connection and wiring dia gram Connection diagram N PE L3 L2 L1 PE N L3 L2 L1 N 2 4 6 N 1 3 5 PE N L3 L2 L1 Fig 28 A Emergency stop mains isolator B ZPK 2 03 PCB C Neutral conductor distribution terminal D Charging control panel optional Note Make earthing cable PE longer t...

Page 40: ...40 1 2 3 Fig 29 Installation sequence Fitting the front casing panels 5679249 Installation ...

Page 41: ...A Height adjusting screw to set vertical position B Front adjusting screw to set horizontal position C Rear adjusting screw to set angle of door Installation sequence Fitting the front casing panels cont 5679249 Installation ...

Page 42: ...42 1 2 3 4 Fig 31 Note Secure each side panel from above with 2 screws M4x20 Installation sequence Fitting the side casing panels 5679249 Installation ...

Page 43: ...43 1 2 3 4 Fig 32 Installation sequence Fitting the rear casing panels 5679249 Installation ...

Page 44: ... 1 2 Fig 33 Note Secure each panel with 4 screws M4x20 Affixing the type plate Fig 34 Affix the type plate to the l h casing panel Installation sequence Fitting the top casing panels 5679249 Installation ...

Page 45: ...s fan 77 15 Cleaning the Lambda probe 77 16 Cleaning the flue gas collector chamber 79 17 Checking the heat exchanger cleaning 79 18 Cleaning the ash chamber and ash removal 84 19 Cleaning the light barriers and sight glasses 85 20 Checking the expansion vessel and system pressure 85 21 Servicing safety valves and checking they are working 86 22 Cleaning flue system and checking it is working corr...

Page 46: ...00 2 0 mol m3 11 2 dH 1 5 mol m3 8 4 dH 0 02 mol m3 0 11 dH Fig 35 1 Check the pre charge pressure of the expansion vessel If the pre charge pressure is lower than the static system pressure top up with nitrogen until the pre charge pressure is 0 1 to 0 2 bar 10 to 20 kPa higher than the static system pressure If the pre charge pressure is too high adjust it accordingly 2 Open the non return valve...

Page 47: ...l unit start up Press Ù and Ú simultaneously for approx 5 seconds When the unit is first commissioned the display is in German Sprache Dansk Cesky Bulgarski Deutsch Wählen mit ê ê ç DE BG CZ DK ê ê Fig 36 Manually switching some appliance components dur ing commissioning enables the control unit to display messages These messages are not appliance faults Commissioning sequence overview Depending o...

Page 48: ... diagnosis sensors Check outputs actuators Calibrate O2 probe Lambda probe Fill vacuum module optional Terminate the commissioning sequence commis sioning completed Setting the language Shortly after switching the power on the display shows Select language Press the following buttons 1 for the required language 2 d to confirm Enter iD number optional Press the following buttons 1 for the required ...

Page 49: ...lecting a cascade only the following configu rations are available Boiler number 1 Pellet store sensor Additional boiler Connection for heating circuits DHW DHW circula tion and solar Boiler numbers 2 3 or 4 Pellet store sensor Selecting cascade charging Available if cascade with boiler number 1 2 3 or 4 was previously selected Press the following keys 1 if common charging of the Boiler cascade is...

Page 50: ...uum module dis charge screw conveyor 214 216 218 240 241 243 244 245 248 251 10 Rotary lock valve vacuum module mole 214 215 216 241 243 245 248 251 11 Rotary lock valve vacuum module ex traction screw conveyor 214 215 216 241 243 245 248 251 12 External charging control panel with hydraulics transverse screw conveyor and screw conveyor 222 246 CAN 13 External charging control panel with rotary lo...

Page 51: ...Safety limit switch silo door 246 Fault external charging Charging scheme 1 Flexible agitator discharge Boiler is charged via flexible agitator discharge Fig 38 Outputs Plug number Function 218 Motor flexible agitator discharge Inputs Plug number Function 240 Limit switch flexible agitator discharge 241 Safety limit switch silo door 244 Thermal contact flexible agitator discharge Commissioning ins...

Page 52: ...er screw conveyor 239 Limit switch screw conveyor 241 Safety limit switch silo door 243 Thermal contact screw conveyor 246 Fault external charging Charging scheme 3 Screw conveyor and flexible agitator discharge Boiler is charged via screw conveyor and flexible agita tor discharge Fig 40 Outputs Plug number Function 216 Screw conveyor motor 218 Motor flexible agitator discharge Commissioning inspe...

Page 53: ...ischarge screw conveyor and agita tor Boiler is charged via horizontal discharge screw con veyor and agitator Fig 41 Outputs Plug number Function 216 Screw conveyor motor 218 Motor agitator Inputs Plug number Function 236 Light barrier screw conveyor 239 Limit switch screw conveyor 240 Limit switch agitator 241 Safety limit switch silo door 243 Thermal contact screw conveyor 244 Thermal contact ag...

Page 54: ...lug number Function 241 Safety limit switch silo door 243 Thermal contact rotary lock valve 245 Thermal contact vacuum module 248 Proximity switch pellet hopper Charging scheme 7 Rotary lock valve and pellet hopper with vacuum module and changeover unit Boiler charging via a rotary lock valve and a pellet hop per The pellet hopper is filled via a vacuum module and automatic changeover unit Fig 43 ...

Page 55: ...charging Boiler charging via a rotary lock valve and a pellet hop per The pellet hopper is filled via a vacuum module and external charging ext Fig 44 Outputs Plug number Function 214 Motor vacuum module 216 Motor rotary lock valve 222 External charging potential free Inputs Plug number Function 241 Safety limit switch silo door 243 Thermal contact rotary lock valve 245 Thermal contact vacuum modu...

Page 56: ...n 214 Motor vacuum module 216 Motor rotary lock valve 218 Motor discharge screw conveyor Inputs Plug number Function 240 Safety limit switch discharge screw conveyor 241 Safety limit switch silo door 243 Thermal contact rotary lock valve 244 Thermal contact discharge screw conveyor 245 Thermal contact vacuum module 248 Proximity switch pellet hopper 251 Proximity switch suction shoe transition Com...

Page 57: ...Function 241 Safety limit switch silo door 243 Thermal contact rotary lock valve 245 Thermal contact vacuum module 248 Proximity switch pellet hopper 251 Proximity switch suction shoe transition Charging scheme 11 Rotary lock valve and pellet hopper with vacuum module and extraction screw conveyor Boiler charging via a rotary lock valve and a pellet hop per The pellet hopper is filled via a vacuum...

Page 58: ...c push floor with transverse screw conveyor The dosing hopper is charged via a screw conveyor and a hydraulic push floor with transverse screw con veyor This is regulated via an external charging control panel Material requests and fault messages are sent via digi tal signals The parameters of the charging control panel can be changed via the CAN interface ext CAN Fig 48 Outputs Plug number Functi...

Page 59: ...ug number Function 222 External charging demand Inputs Plug number Function CAN Communication with charging control panel 246 Fault external charging Selecting the type of changeover unit Available if charging scheme With changeover unit was previously selected Press the following buttons 1 0 for Changeover unit with backwash function 4 way or 8 way or 1 for Changeover unit with bypass func tion w...

Page 60: ...store press the following buttons 1 for pellet store sensor Yes No 2 d to confirm Set flue gas filter Press the following buttons 1 No if no flue gas filter is installed or External for demand to flue gas filter and fault message from flue gas filter via floating contact or Internal for control of flue gas filter via CAN bus 2 d to confirm Selecting external digital input Available if No was selec...

Page 61: ...oint for capturing the system tempera ture from the top or 1st temperature sensor to the 2nd temperature sensor in the heating water buffer cyl inder select buffer type 1 1 for buffer type 2 d to confirm Setting the heating water buffer cylinder minimum temperature top Available if 1 was selected for the buffer type Press the following buttons 1 for setting the minimum temperature of the top or fi...

Page 62: ...tional boiler Yes were selected Press the following buttons 1 Heating water buffer cylinder charging up to the temperature sensor of the heating water buffer cylinder 0 1 2 3 4 or 5 2 d to confirm Setting the buffer charging temperature by an additional boiler Available if buffer charging by additional boiler up to buffer temperature sensor 0 was selected Press the following buttons 1 for the requ...

Page 63: ...e following buttons 1 Not connected for Not installed or DHW heating connected to a combi cylinder or On the boiler for Connected at internal PCB or On the mixer module for Connected to extension kit via KM BUS 2 d to confirm Selecting DHW circulation Available if DHW connection On the boiler was selected or a further group is available on the HKK PCB To specify whether a DHW circulation pump is c...

Page 64: ...or Not installed or On the boiler for Connected at internal PCB 2 d to confirm Setting the solar DHW maximum temperature Available if previously Solar on boiler and DHW were selected or Buffer type 1 was selected Press the following buttons 1 for the required max DHW temperature 2 d to confirm Setting the maximum solar collector temperature Available if Solar on boiler was selected Press the follo...

Page 65: ...circuit designations Available if a heating circuit has been set Press the following buttons 1 to change the letters 2 Ù Ú to select the next character 3 d to confirm Checking operating states and sensors diagnostics Depending on the previous setting other displays will be available Check temperature values or states of all inputs for function and logic Examples of function and logic Are the tempe...

Page 66: ...the corresponding actuator which will be carried out If no action or the wrong action appears check the cor responding electrical connection Press d to continue to the next display General Central fault Open Output On Boiler Flue gas fan On Ignition On Prim air damper Open Prim air damper Close Sec air damper Open Sec air damper Close Boiler pump On Boiler valve Open Boiler valve Close Ash removal...

Page 67: ...e structure of the commissioning menu is dis played Pressing å switches to the standard menu Setting supply times for the vacuum system You can individually set specific times during which you do not want fuel to be supplied Operating instructions Matching the control unit to the heating system The control unit must be matched to the system equip ment level Various system components are recog nise...

Page 68: ...et room temperature The set room temperature can be adjusted separately for each heating circuit The heating curve is offset along the set room temper ature axis With the heating circuit pump logic function active the curve modifies the start and stop character istics of the heating circuit pump Standard room temperature D E B C A 110 20 C 26 C 20 C 26 20 Fig 51 Changing the standard room temperat...

Page 69: ...curve can be adjusted separately for each heating circuit A B Boiler water or flow temperature in C 110 20 20 Outside temperature in C 3 5 1 4 0 2 Fig 53 A Changing the slope B Changing the level vertical parallel offset of the heating curve Press the following buttons 1 å 2 for selecting the heating circuit 3 d to confirm 4 for Heating curve 5 d to confirm 6 for Slope or Level 7 d to confirm 8 fo...

Page 70: ...es and fluids can lead to burns or scalding Before maintenance and cleaning work switch OFF the system and let it cool down Never touch hot surfaces on the boiler burner flue system or pipework Wear suitable personal protective equipment Danger Hot surfaces and fire from apertures can result in severe burns Doors covers and apertures fastened shut with screws must not be opened during heat ing ope...

Page 71: ...an 77 X Cleaning Lambda probe 77 X Cleaning the flue gas collector chamber 79 X Check heat exchanger pipes and heat exchanger cleaning 79 X Clean the ash chamber and ash removal parts 84 X Check light barriers and sight glasses 85 X Check expansion vessel and system pressure 85 X Service the safety valves and check their operation 86 X Cleaning flue system and checking it is working correctly 86 X...

Page 72: ...n fireproof con tainers with covers Danger Wood dust pellet dust cinders and soot pose a risk to the eyes skin and airways Wear suitable personal protective equipment especially breathing equipment and safety gog gles Ash box data Empty 16 kg Full Approx 40 kg Remove the ash box B C A 3 1 2 5 D 4 6 E Fig 54 1 Press and hold down spring clip A 2 Pull open locking handle B 3 Fold clamping clip C to ...

Page 73: ...3 Push ash partition E in the direction of the arrow until pin D locks home in the next hole 4 Push ash box towards the boiler Note The boiler can only be started when the safety switch is pushed in and locked into place 5 Hook in clamping clip C 6 Push locking handle B into closed position Commissioning inspection maintenance Emptying the ash box cont 5679249 ...

Page 74: ...en the front door 2 Open the combustion chamber door 3 Note Do not push ash on the combustion chamber bricks onto the grate Clean combustion chamber A with a vacuum cleaner Commissioning inspection maintenance Cleaning the combustion chamber 5679249 ...

Page 75: ...e grate must be horizontal in the end position The gap between the grid elements must not be too large 1 2 3 4 Fig 57 1 Remove casing panel 2 Open the grate maintenance cover 3 Clean the grate with the scraper accessory 4 Check the grate end position Note The grate elements must be horizontal in the end position Check the grate limit switch if applicable Commissioning inspection maintenance Checki...

Page 76: ... the grate is not horizontal in the end position If the gap between the grid elements is too large 5 6 Fig 58 5 Remove left hand casing 6 The gear for actuating the grate limit switch must be in the switching position Note The switching position of the limit switch is imple mented as a bore in the middle gear Commissioning inspection maintenance Checking the grate end position and cleaning cont 56...

Page 77: ...eller imbalance deposits on the impeller vanes The boiler output is reduced 1 2 3 Fig 59 Note Remove the top casing panels 3 Remove the fan Clean the flue gas fan impeller with a soft brush and a vacuum cleaner and check for damage Cleaning the Lambda probe Danger Hot Lambda probe may cause burns Allow the Lambda probe to cool down before removing Wear safety gloves Commissioning inspection mainte...

Page 78: ...e top casing panels 2 Unhook casing panel 3 Remove Lambda probe C clean with a soft brush and check for damage Note Use the Lambda probe key provided Commissioning inspection maintenance Cleaning the Lambda probe cont 5679249 ...

Page 79: ... components can result in life threatening injuries After switching off the ON OFF switch on the control unit there are still live components inside the control unit enclo sure 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 Safeguard the system against reconnection Danger Risk of crushing or entanglemen...

Page 80: ...4 Check the heat exchanger cleaning Switch on the system Do not start the boiler Switch the heat exchanger cleaning by means of an actuator test Isolate the system from the power supply and check that it is no longer live Safeguard the system against reconnection Note The heat exchanger cleaning can be switched via Actuator test in the Service menu See page 113 Commissioning inspection maintenance...

Page 81: ...xchanger if required Removing the turbulators 6x 4x 4x 2x 1 2 3 Fig 63 1 Pull out the spring pin 2 Pull out the bolts 3 Remove the cover Commissioning inspection maintenance Checking the heat exchanger cleaning cont 5679249 ...

Page 82: ...82 4 Fig 64 4 Lift the turbulators slightly off the rocker one by one and let them slide into the pipes Commissioning inspection maintenance Checking the heat exchanger cleaning cont 5679249 ...

Page 83: ...rds one by one Cleaning the heat exchanger and 2nd flue 1 Clean the heat exchanger with a cleaning brush and vacuum cleaner 2 Remove the cover from the 2nd flue 3 Clean the 2nd flue Commissioning inspection maintenance Checking the heat exchanger cleaning cont 5679249 ...

Page 84: ...move the ash box 2 Remove casing panel 3 Dismantle ash removal cover 4 Clean the ash chamber with a vacuum cleaner 5 If necessary clean the screw conveyors with a cleaning brush Commissioning inspection maintenance Cleaning the ash chamber and ash removal 5679249 ...

Page 85: ... boiler heats up the pressure rises to 2 or 3 bar 0 2 or 0 3 MPa The safety valve may also respond and discharge the excess pressure Therefore check the expansion vessel pre charge pressure annually Check whether the installed expansion vessel is ade quate for the system water volume GB only Carry out this test on a cold system 1 Drain the system until 0 is shown on the pressure indicator 2 If the...

Page 86: ...ow rate is low clean the valve or replace if required Cleaning flue system and checking it is working correctly Danger Leaking or blocked flue systems or an insuffi cient combustion air supply can cause life threatening poisoning from flue gas and carbon monoxide Ensure the flue system is in good working order Apertures for combustion air supply must be non closable The system may only be commissi...

Page 87: ...se or by means of a mains isolator and check that it is no longer live Safeguard the system against reconnection Danger Risk of crushing or entanglement due to rotating and moving parts Do not reach in through the maintenance cov ers Checking operating states actuators and sensors Switch on the system Do not start the boiler Check operating states in the Diagnosis menu Check sensors are firmly sea...

Page 88: ...t transfer must be ensured 2 Recommendation Start the boiler and heat for approx 45 minutes Boiler water temperature 60 C 3 In the standard menu activate for Test mode The display shows Preparation The boiler heats until load operation Test active appears as soon as constant heating operation has been reached 4 Carry out emissions test 5 Confirm Terminate with d to end the emissions test manually ...

Page 89: ...attery inside the control unit Battery For function and type see page 126 For installation position see page 142 Instructing the system user The system installer should hand the operating instruc tions to the system user and instruct the user in oper ating the system This includes all components installed as accessories e g remote control units In addition the system instal ler must make the user ...

Page 90: ...ay 11 ä until the default display is shown Overview of coding level 1 The coding addresses are displayed in groups subject to system configuration Service function See page Hardware 90 General 94 Boiler 94 Charging 94 Buffer cylinder 97 Additional heat generator 98 Heating 100 DHW 103 Solar 103 Hardware Coding Coding in the delivered condition Possible change Additional boiler Additional boil er N...

Page 91: ...e boiler cas cade Cascade 4 Boiler number 4 in the boiler cas cade Cascade charging Cascade No No common charging of boilers se lected Cascade Screw conveyor The boiler is charged via a screw conveyor This screw conveyor is switched by the external charging control panel Cascade Vacuum module The boiler is charged via a vacuum module The vacuum module is switched by the boiler Changeover unit type...

Page 92: ...lve vac uum module and extraction screw conveyor Charging scheme 12 External charging control panel with hydraulics transverse screw conveyor and screw conveyor Charging scheme 13 External charging control panel with rotary lock valve and pendulum discharge AP including reversal of rotational direction DHW DHW No No DHW heating installed DHW On the boil er DHW heating is connected to the control u...

Page 93: ...rcuit 4 On the boiler Heating circuit is connected to the boiler control unit Heating circuit 4 On the mixer module Heating circuit is connected to the extension kit Shut off gate valve Shut off gate v No No shut off gate valve installed Shut off gate v Yes Shut off gate valve installed Fuel store sensor Silo sensor No No level sensor installed in the fuel store Silo sensor Yes Level sensor instal...

Page 94: ... the flue gas fan in of the max speed 3D 15 to 3D 100 Setting range in Flue gas fan maximum speed 3E Max speed of the flue gas fan in of the max speed 3E 20 to 3E 100 Setting range in Minimum flue gas temperature 3F 80 Minimum set boiler flue gas tem perature 80 C 3F 50 to 3F 150 Setting range in C Set system temperature 45 1 A min set system temperature can be set for the boiler 45 0 The min set ...

Page 95: ...ing range in minutes Flue gas filter maximum voltage DA Max voltage of the electrostatic flue gas filter DA 15 to DA 30 Setting range in kV Charging Different codes will be available depending on the set Charging scheme Coding Coding in the delivered condition Possible change Dosing hopper idle runtime 02 5 Idle runtime of dosing hopper 5 seconds 02 0 to 02 100 Setting range in seconds Combustion ...

Page 96: ...9 0 to 29 250 Setting range in seconds Vacuum module pre flushing time 2A 10 Pre flushing time of 10 seconds 2A 0 to 2A 60 Setting range in seconds Vacuum module post flushing time 2B 10 Post flushing time of 10 seconds 2B 0 to 2B 60 Setting range in seconds Day hopper idle runtime 2C 15 Idle runtime 15 min 2C 1 to 2C 600 Setting range in min Screw conveyor delay 2E 2 Delay of 2 seconds 2E 0 to 2E...

Page 97: ...harge BE 0 to BE 1 0 No 1 Yes Delay hydraulic drive unit C1 Delay to hydraulic drive unit C1 0 to C1 300 Setting range in seconds Transverse screw conveyor emergency mode delay C2 Emergency mode delay of the transverse screw conveyor C2 0 to C2 1000 Setting range in seconds Hydraulic drive unit emergency mode C3 2 Emergency mode delay of the hy draulic drive unit C3 0 to C3 250 Setting range in se...

Page 98: ...buffer cylinder until the temper ature of 60 C is reached at the se lected sensor code 36 1 5 buf fer cylinder group 37 30 to 37 100 Setting range in C Boiler start sensor 39 1 If the set system temperature at the 1st buffer temperature sensor is undershot the boiler starts 39 2 If the set system temperature at the 2nd buffer temperature sensor top is undershot the boiler starts 39 3 If the set sy...

Page 99: ...r temperature sensor 4 D0 5 The additional heat generator charg es the heating water buffer cylinder up to buffer temperature sensor 5 Buffer charging until temp D1 75 The additional heat generator charges the heating water buffer cylinder until the temperature of 75 C at the selected sensor code D0 1 5 is reached D1 50 to D1 100 Adjustable value in C Start delay D2 10 Start delay of the additiona...

Page 100: ...ding in the delivered condition Possible change Remote control A0 0 Available if a remote control unit is connected Without remote control A0 1 With Vitotrol 200 A Recognised automatically A0 2 With Vitotrol 300 A Recognised automatically A0 3 With Vitotrol 350 Recognised automatically Summer eco function room temperature A5 5 With heating circuit pump logic function economy mode Heating circuit p...

Page 101: ...ng circuit pump logic Heating circuit pump also OFF The mixer has been attempting to close for longer than 20 minutes Heating circuit pump ON for the following functions If the heating mixer changes to control function If there is a risk of frost Room sensor room hook up B0 0 Available if code A0 0 is set in the current Heating group Heating mode and reduced mode Weather compensated mode without r...

Page 102: ...K 3 RTactual RTset 3 K RTactual RTset 2 K 4 RTactual RTset 2 K RTactual RTset 1 K 5 RTactual RTset 1 K RTactual RTset 6 RTactual RTset RTactual RTset 1 K 7 RTactual RTset 1 K RTactual RTset 2 K 8 RTactual RTset 2 K RTactual RTset 3 K Coding in the delivered condition Possible change Flow temperature minimum limit C5 20 Minimum flow temperature limit C5 1 to C5 100 Adjustable value in C Flow temper...

Page 103: ...stable value in C DHW return temperature 0D 10 Flow control enabled Set return temperature corre sponds to DHW temperature plus 10 C 0D 0 Flow control deactivated Valve is always fully opened 0D 1 to 0D 30 Flow control enabled Set return temperature corresponds to DHW temperature plus selected value Adjustable value in C Solar Coding Coding in the delivered condition Possible change Differential D...

Page 104: ... 23 00 h 71 23 The time of the function must be within the enable times for DHW heating Additional function runtime 72 0 Circulation pump for heat transfer Off 72 0 to 72 180 Running time of the circulation pump for solar heat transfer Adjustable value in minutes Only active in conjunction with code 71 1 23 Solar circuit pump maximum speed 73 100 Maximum permissible speed of so lar circuit pump ou...

Page 105: ...ipment level or the setting of other codes are not displayed Press the following buttons 1 d å simultaneously for approx 4 s The Service menu appears 2 ä d simultaneously for approx 4 s Code 2 appears in the Service menu 3 for Code 2 4 d to confirm 5 for the required group 6 d to confirm 7 Ù Ú for Heating for Heating circuit 1 HC1 Heating circuit 2 HC2 Heating circuit 3 HC3 or Heating circuit 4 HC...

Page 106: ...ment Low set value Slow adjustment High set value 1 increment 10 minutes Outside temperature offset 92 0 No outside temperature correction 92 10 to 92 10 Outside temperature correction Adjustable value in C Boiler Coding Coding in the delivered condition Possible change Flue gas residual O2 partial load correction 0D Corrects the selected O2 set value in the flue gas by the selected on a modulatin...

Page 107: ...Delay of fuel delivery in seconds on fuel ignition 4A 1 to 4A 420 Setting range in seconds Light barrier firebed cycle ramp 52 Cycle ramp setting for the feed screw conveyor when firebed light barrier is interrupted in seconds 52 1 to 52 50 Setting range in seconds Material controller flue gas fan 55 Factor for varying fan speed 55 0 to 55 50 Setting range without unit Material controller minimum ...

Page 108: ...ambda probe heating Calibration of Lambda probe manual only F9 0 Lambda probe heating always on Calibration of Lambda probe man ual only F9 2 Automatic start of Lambda probe heating Automatic calibration of Lambda probe O2 probe type FF 0 Lambda probe used Type LSM 11 FF 1 Lambda probe used Type NGK FF 2 0 to 20 mA FF 3 Lambda probe used Wideband probe with BLS Charging Different codes will be ava...

Page 109: ...0 Pellet hopper proximity switch only for detecting the maximum fill level in the pellet hopper E8 1 Pellet flow detection replacement pellet flow sensor Heating Coding Coding in the delivered condition Possible change DHW priority A2 0 No priority control during cylinder heating Note Individually adjustable for each heating circuit Select heating circuit with Á A2 1 During cylinder heating the mi...

Page 110: ...ection activate A4 0 The frost protection function is ac tivated Start and stop tempera tures of the function can be adjus ted code A3 Heating group Frost protection function The heat ing circuit pump is switched on at the relevant outside temperature a min flow temperature of 10 C is specified At the relevant outside temperature the frost protection function is automatically switched off A4 1 The...

Page 111: ...ble change Set DHW temperature reheating suppression 67 0 Reheating suppression of solar control unit deactivated 67 1 to 67 90 DHW set value during active reheat ing suppression of the solar control unit in C Start hysteresis DHW 85 0 Pump on As soon as DHWactual DHWset 2 5 K 85 1 to 85 10 Setting range in K Pump on As soon as DHW 1 to 10 K below WWset Controllers Note Changing the controllers is...

Page 112: ...29 Fill vacuum module Vacuum module Filling the pellet hopper Checking 115 Run hopper until empty Setting the interval for running the pellet hopper until emp ty 115 Changeover unit Checking the changeover unit 115 Standard setting Loading the standard setting All data General Boiler Charging Heating water buffer cylinder Additional boiler All groups 117 Terminate service Exit service 112 Calling ...

Page 113: ...s 3 d to confirm 4 d for the required information in the menu 5 ä until the default display is shown Checking the outputs actuators Danger Incorrectly connected actuators can cause dam age to the system During the actuator tests check the respective actuator carefully Danger Activated charging devices feed screw con veyor screw conveyor etc can cause block ages in the fuel discharge system during ...

Page 114: ...er HKK PCB Pump On Valve Open Valve Close Calling up the Actuator test menu The actuator test can only be carried out when the boiler is turned off START STOP button is not illumi nated Outputs actuators can be switched in the Service menu under Actuator test Note Each term on the display is followed by the action of the corresponding actuator which will be carried out If no action or the wrong ac...

Page 115: ...w to start the boiler Automatic The pellet hopper is regularly run until empty Once The pellet hopper is run until empty once After running until empty the setting Run hopper until empty is automatically reset to No Calling up the Run pellet hopper until empty menu 1 d å simultaneously for approx 4 seconds The Service menu appears 2 for Service functions 3 d to confirm 4 for Run hopper until empty...

Page 116: ...et position Required position of the changeover unit Position for suction by the marked suction wand Position for flushing of the left hand suction wand LS LS zero Limit switch at zero point of changeover unit before LS zero indicates that the limit switch is actuated at the zero point of the changeover unit LS LS position Limit switch for the position of the changeover unit per vacuum unit before...

Page 117: ...enu All data The standard settings for all listed menu items are loaded General General standard settings are loaded Boiler Standard settings in the Boiler menu are loaded Fuel Standard settings in the Fuel menu are loaded Charging Standard settings in the Charging menu are loa ded Buffer Standard settings in the Buffer menu are loaded Additional boiler Standard settings of the Additional boiler a...

Page 118: ...ss the following buttons 1 å Menu appears 2 for Fault 3 d to confirm 4 for the list of current faults 5 ä until the default display is shown Calling up fault codes from the fault memory fault history The 10 most recent faults are saved and can be called up Faults are sorted by date Press the following buttons 1 d å simultaneously for approx 4 s The Service menu appears 2 for Fault history 3 d to c...

Page 119: ... ZPK Check the type of auxiliary PCB Check the connection between boiler PCB heating circuit PCB and auxiliary PCB 20 Burner locked out Short circuit boiler water temperature sensor Check boiler water temperature sensor 21 Return temperature raising facility valve opening Boiler circuit pump starts Short circuit boiler return temperature sensor Check boiler return temperature sensor 22 Burner lock...

Page 120: ... for too long Check grate for ease of operation 3C Burner locked out Grate does not reach limit position Check grate for ease of operation 3D Burner locked out Ash box not fitted Check ash box position 3E Burner locked out Current flue gas fan speed does not match set speed Check flue gas fan 3F Burner locked out Too little water in the ex tinguishing water tank Top up with water 41 No control mod...

Page 121: ... cuit 4 Check flow temperature sensor heating circuit 4 61 No control mode at heating circuit 1 Lead break flow tempera ture sensor heating cir cuit 1 Check flow temperature sensor heating circuit 1 62 No control mode at heating circuit 2 Lead break flow tempera ture sensor heating circuit 2 Check flow temperature sensor heating circuit 2 63 No control mode at heating circuit 3 Lead break flow tem...

Page 122: ...cessary See chapter Maintenance 93 Burner locked out Residual O2 flue gas value is too high during load op eration Top up the day hopper if necessary Check installation of ash box 9A Burner locked out The door contact of the flue gas filter has been in terrupted No feedback from the high voltage module Close the flue gas filter door 9B Flue gas filter not working The breakdown voltage at the flue ...

Page 123: ...o time out The blocking time set for the vacuum module is too long Adjust the vacuum module block ing time in the control unit The fault is cleared after the block ing time and the boiler is started A6 Burner locked out Ash box full Emptying the ash box Confirm message Has the ash box been emptied Note The ash box fill level can be reset manually as follows 1 å for Menu 2 to select 3 Confirm Infor...

Page 124: ...ck maintenance cover of screw conveyor BC Burner locked out Maintenance cover of dis charge open Check maintenance cover of dis charge BD Burner locked out Maintenance cover door of fuel store open Check maintenance cover door of fuel store BE Burner locked out Proximity switch at dis charge screw conveyor is permanently active Clean sensor if possible BF Burner locked out Rotary lock valve motor ...

Page 125: ...t exchanger cleaning did not reach limit position Check the limit switch for heat exchanger cleaning Check heat exchanger cleaning F8 Burner locked out Ash removal screw con veyor has gone into re verse too often Check ash removal screw convey or and ash box F9 Burner locked out Grate did not reach limit position Acknowledge a fault If fault recurs check grate Clean grate if necessary FA Burner lo...

Page 126: ...n nection and wiring diagram Danger Using the wrong fuses or inserting them incorrectly can lead to an increased risk of fire Do not use force to insert the fuses Posi tion the fuses correctly Only use structurally identical types with the stated response characteristics Battery The battery serves to save the time and date in the event of a power failure Button cell type CR2032 3 V Replacement Eve...

Page 127: ... that the thermally activated safety valve is reset A B Fig 69 1 Move cover A on the programming unit to the right 2 Press green button B of the high limit safety cut out A faint click will be audible the high limit safety cut out is reset 3 Close cover A on the programming unit 4 Acknowledge excess temperature at the program ming unit with d Sensors Sensor type Pt1000 Flow temperature sensor Buff...

Page 128: ...5 1 20 50 Fig 71 1 Pull out corresponding plug 2 Check the sensor resistance at the plug 3 Compare the result with the actual temperature for scanning see chapter Diagnosis In the case of severe deviation check sensor installation and replace the sensor if necessary Lambda probe For measuring the residual oxygen content in the flue gas Check Lambda probe 1 Check the Lambda probe for dirt and damag...

Page 129: ...al protective equipment in particular protective gloves Requirements Boiler not in operation Flue gas temperature 50 C Check Lambda probe 1 Disconnect the Lambda probe plug Remove the Lambda probe from the flue pipe 2 Check the Lambda probe for contamination and damage Clean if necessary 3 Reconnect the Lambda probe plug 4 Call up the service menu on the control unit Probe heating is activated aut...

Page 130: ...ip 350 to 900 C Externally 40 to 100 C Extension kit for heating circuit with mixer Extension kit type Mixer mounting Wall mounting Components Mixer motor with connecting cable Plug for connecting the heating circuit pump Flow temperature sensor contact temperature sen sor Flow temperature sensor Sensor type NTC 10 kΩ at 25 C Protection rating IP 53 to EN 60529 ensure through design installation P...

Page 131: ...motor if required Danger Touching live components can result in life threatening injuries Isolate the appliance from the power supply before opening e g at a separate MCB fuse or a mains isolator and check that it is no lon ger live Safeguard the appliance against reconnection 1 Remove the top casing cover of the extension kit gS BU Fig 74 2 Replace the wires in the terminals and on the plug gS 3 ...

Page 132: ... boiler is off no frost protection Illuminated The boiler is in standby mode and will start automatically on demand or the boiler is in operation Flashing The boiler completely burns the available fuel or An external demand via coding address 44 was activated Note The START STOP button is disabled if an external programming unit is con nected The boiler can only be switched on and off via the exte...

Page 133: ...unit uses the buffer charg ing level to calculate the set value for the combustion output of the boiler Optimum settings of the heating system have a posi tive effect on the service life and efficiency of the boiler Positive influencing factors are Low start up frequency High combustion output Guideline values for load operation 80 full load 20 partial load Longest possible runtime of the boiler n...

Page 134: ...erating mode During the set time phases the charging level of the heating water buffer cylinder has an effect on the boiler operation Operating modes operating program The operating modes Automatic Manual and Off are available for regulating the heating water buffer cylinder The influence of the operating modes on the combus tion output of the boiler in turn influences the runtime and the start up...

Page 135: ...ure sensor The flow temperature is regulated by the stepped opening or closing of the mixers The mixer motor control changes the actuating and pause times subject to the control differential control deviation Coding addresses Coding addresses that influence heating circuit con trol A0 to FB For a description see the relevant coding address in chapter Codes The set flow temperature of each heating ...

Page 136: ...s B5 Frost protection If the outside temperature falls below 1 C a flow temperature of at least 10 C is ensured To adjust the setting see coding address A3 variable frost protection limit Transfer excess heat The heating circuit is regulated to the set max flow temperature coding address C6 provided that the boiler is set to status Transfer excess heat and coding address F3 is set to 1 Screed dryi...

Page 137: ... temperature Every operating mode has its own set level Outside temperature A heating curve must be set to adjust the control unit to the building and the heating system See chapter Adjusting heating curves The heating curve characteristics determine the set flow temperature subject to the outside temperature and regulate based on the average outside tempera ture This is made up of the actual and ...

Page 138: ...selected value is exceeded the temperature limiter stops the heating circuit pump The flow tem perature decreases only slowly i e it may be several hours before the system restarts automatically Lower control range limit Electronic minimum temperature limit Setting range 10 to 100 C Change via coding address C5 Only active during operation with standard room tem perature Cylinder temperature contr...

Page 139: ...ontrol unit continues to oper ate with the same set value Set DHW temperature The set DHW temperature can be adjusted between 10 C and 70 C DHW circulation pump The DHW circulation pump delivers hot water to the draw off points at adjustable times Up to 4 time phases can be set at the time switch Reheating suppression A second set DHW temperature can be specified via coding address 67 Reheating by...

Page 140: ...imes have been configured at the programming unit a supply process cannot be initiated during a blocking time If required the pellet sensor can initiate a supply process before a blocking time starts to completely refill the pellet hopper If the supply process was initiated the vacuum module is initially activated Pellets that remain in the pipework from the previous supply process are removed Aft...

Page 141: ... E Control mode F Burnout phase G Boiler cleaning H Idle state A Control mode ag1 Flushing speed ag2 Ignition speed e1 Charge time entry e1 Fill time entry if necessary z Ignition on For Vitoligno 300 H only from C l1 Air damper calibration l2 Air damper flushing position l3 Air damper ignition position w1 Heat exchanger cleaning 5 r1 Grate cleaning 5 ea Ash removal motor 5 5 Control time varies d...

Page 142: ... live Safeguard the system against reconnection A 1 2 Fig 86 A PCBs in the control unit wiring chamber ZPK 2 03 Auxiliary PCB Control of the fuel charging and cleaning systems HKK 2 01 Heating circuit PCB Control of the heating cir cuits DHW heating and solar KSK 2 03 Main PCB Burner control unit KM BUS CAN bus buffer temperature sensors control of automatic return temperature raising facility 1 R...

Page 143: ... GND 0 20mA 0 20mA 0 10V 20mA 0 10V 20mA 1 2 1 2 1 2 1 2 3 1 2 3 4 1 2 3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Fig 88 sCF Light barrier receiver feed sCD Light barrier transmitter feed sCH Light barrier receiver screw conveyor sCG Light barrier transmitter screw conveyor sCJ Shut off gate valve motor sCJA Shut off gate valve limit switch sCK Limit switch feed sCL Input limit switch screw con...

Page 144: ...on 0 10 V C Jumper for parameter settings input s H Delivered condition 0 10 V D Jumper for parameter settings output s A 0 10 V or PWM Delivered condition 0 10 V E Jumper for parameter settings output s G GSCHN or GMOT Delivered condition GMOT Allocation of terminals plug sBÖ 1 24 V 2 Input zero point 3 Input position 4 Proximity switch pellet hose Information on the jumpers Jumper A for input s ...

Page 145: ...yor motor sYF Suction turbine motor s Ö 6 Connection to HKK PCB sXS External charging demand sYL Operating message sYG Changeover unit motor sYD Feed motor sYH Motor screw conveyor or rotary lock valve sYK Motor flexible agitator discharge sYÖ Power supply Note The slot assignment on this PCB may differ subject to the system version System specific slot assignment System examples 6 Internally prew...

Page 146: ...g circuit 3 d F SOL Cylinder temperature sensor solar d Ö SOL Default speed for solar circuit pump A Jumper for parameter settings output d Ö Factory setting Closed PWM solar circuit pump Note The slot assignment on this PCB may differ subject to the system version Information on the jumpers Jumper A for output d Ö 0 10 V PWM Jumper at top Voltage signal 0 10 V 0 10 V PWM Jumper at bottom PWM sign...

Page 147: ...ting dXA HC 2 Valve heating circuit 2 or UP Circulation pump DHW cylinder transfer of heat Y1 or ZP DHW circulation pump Y2 or UP and ZP dCÖ HC 3 Pump heating circuit 3 or TWE Cylinder loading pump circulation pump for cylinder heating or SOL Solar circuit pump dCA HC 3 Valve heating circuit 3 or SOL Diverter valve solar or UP Circulation pump DHW cylinder transfer of heat Y1 or ZP DHW circulation...

Page 148: ... 0 20mA AO GND 0 20mA 0 20mA AO GND 5 4 2 3 1 2 1 5 6 3 4 1 2 3 4 1 2 AI GND AI GND AI AI GND 13V 13V 2 1 4 10 Fig 92 Outside temperature sensor 6 Flow temperature sensor Buffer temperature sensors aG 6 Flue gas temperature sensor aJ 6 Return temperature sensor sL 6 Boiler circuit pump sLB 6 Speed boiler circuit pump kSA 6 Limit switch heat exchanger cleaning option lJ 6 Jumper fitted lK 6 Jumper ...

Page 149: ...pers Jumper A for CAN input 120 Ω Jumper open No CAN terminator 120 Ω Jumper closed CAN terminator 120 Ω Jumper B for input a L 20 mA Jumper open Voltage signal 0 10 V 20 mA Jumper closed Do not use Jumper C for output a ÖB 0 10 V PWM Jumper at top Voltage signal 0 10 V 0 10 V PWM Jumper at bottom PWM signal Jumper D for output sLB 0 10 V PWM Jumper at top Voltage signal 0 10 V 0 10 V PWM Jumper a...

Page 150: ...fer cylinder control valve or screw conveyor motor for ash removal option a S 6 Mixer motor return temperature raising facility s Ö 6 Connection to HKK PCB Electrical installation Requirements The electrical installation should be carried out in accordance with the wiring diagram In the vicinity of hot parts flue gas fan flue pipe cables must be routed in steel pipes and with appropriate clearance...

Page 151: ...sor ash removal S LifYY 3 0 34 2 0 150 High limit safety cut out STB H05VV F G H05RN F G 7 0 75 1 4 232 Light barrier combustion chamber receiver Li9Y11Y HF 4 0 34 2 65 211 Grate motor H05VV F G H05RN F G 4 0 75 2 0 290 Sensor grate position Li9Y11Y HF 3 0 34 2 0 234 Light barrier feed receiver Li9Y11Y HF 4 0 34 2 85 233 Light barrier feed transmitter Li9Y11Y HF 4 0 34 2 4 269 Feed tube temperatur...

Page 152: ...G H05RN F G 3 0 75 6 5 214 Suction turbine H05VV F G H05RN F G 3 0 75 222 Demand external charging H03VV F H03RN F 2 0 75 219 Operating message H03VV F H03RN F 2 0 75 270 External demand H03VV F H03RN F 2 0 75 280 Default output H03VV F H03RN F 2 0 75 281 Output H03VV F H03RN F 2 0 75 152 Water pressure H03VV F G H03RN F G 3 0 75 153 Water shortage H03VV F G H03RN F G 3 0 75 50A Central fault mess...

Page 153: ...Maintenance service Date By Maintenance service Maintenance service Maintenance service Date By Maintenance service Maintenance service Maintenance service Date By Maintenance service Maintenance service Maintenance service Date By Commissioning service reports Commissioning service reports 5679249 Appendix ...

Page 154: ...ections at the back mm 2044 2044 Overall width without light barrier mm 1135 1135 Total width with feed screw conveyor mm 1135 1135 Total height mm 1870 1870 Top edge of flue pipe mm 1565 1565 Minimum boiler transport dimensions Length 13 mm 795 795 Width mm 1145 13 1145 13 Height mm 1654 13 1654 13 Minimum room height mm 2100 2100 Transport weight Basic boiler kg 890 890 Thermal insulation kg 77 ...

Page 155: ...ler rooms standard ambient conditions C 0 to 35 0 to 35 During storage and transport C 20 to 65 20 to 65 Electrical data Rated voltage V 400 400 Rated frequency Hz 50 50 Max rated current A 10 10 Power consumption Ignition W 1400 1400 Ash removal W 25 25 Feed W 380 380 Flue gas fan W 100 100 Grate drive W 14 14 Heat exchanger cleaning W 14 14 Boiler at QN W 234 259 Boiler at Qmin W 122 122 Boiler ...

Page 156: ...e gas mass flow rate damp 15 QN M5 O2 6 kg s 0 028 0 034 g s 28 34 QN M30 O2 8 kg s 0 036 0 043 g s 36 43 Flue gas flow rate 15 QN M5 O2 6 m3 s 0 03 0 04 QN M30 O2 8 m3 s 0 04 0 05 Flue outlet 7 mm 150 150 Required draught At QN mbar 0 05 0 05 Pa 5 5 At Qmin mbar 0 03 0 03 Pa 3 3 Max permissible draught requirement mbar 0 15 0 15 Pa 15 15 Efficiency At full load 93 0 94 4 At partial load 92 0 92 0...

Page 157: ...M 7133 Moisture content M20 W20 M30 W30 Grain size P16S G30 P31S G50 Approved wood pellets To EN ISO 17225 2 Quality A1 Diameter 6 mm For further information about the fuel Boiler operating instructions Specification Specification cont 5679249 Appendix ...

Page 158: ...not part of ordi nary household waste For decommissioning the system isolate the system from the power supply and allow components to cool down where appropriate All components must be disposed of correctly Decommissioning and disposal Final decommissioning and disposal 5679249 Appendix ...

Page 159: ...ies with the European directives and supplementary national requirements in terms of its design and operational characteristics Using the serial number the full Declaration of Con formity can be found on the following website www viessmann co uk eu conformity Certificates Declaration of conformity 5679249 Appendix ...

Page 160: ...actuators and sensors 113 Diagnosis menu 113 Diaphragm expansion vessel 85 Display 132 Display elements 132 E Economy mode 136 Ecotronic Connection options overview 37 Electrical connections 29 Assignment on PCB HKK and extension kits KM BUS 36 Electrical connection 30 Overview of electrical connections 31 Power supply 39 Routing cables 29 Electrical installation 150 Extended economy mode 136 Exte...

Page 161: ...ture 137 Overview of electrical connections Connecting heat distribution 32 Connecting outside temperature sensor 31 Connecting the buffer temperature sensor 32 Other electrical connections 38 P PCBs HKK 2 01 146 KSK 2 03 148 Position 142 ZPK 2 03 143 Pellet changeover unit connection in control unit Limit switch 144 Pellet hopper running until empty 115 Pellet supply process 140 Power cable 39 Po...

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Page 163: ...163 5679249 ...

Page 164: ... Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5679249 Subject to technical modifications ...