Viessmann VITODENS 300 WB3A Operating instructions

VIESMANN
Installation instructions
for heating engineers
Vitodens 300
Type WB3A,49and66kW
Gas fired wall mounted condensing boiler
natural gas and LPG version
VITODENS 300
5862 570 GB 5/2004 Dispose after installation

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
!Important information
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the words "Note"
contain additional information.
Safety regulations
Installation, initial start-up, inspection,
maintenance and repairs must be car-
ried out by a competent person
(heating engineer/installation contrac-
tor).
Observe all current safety regulations
as defined by DIN, EN, DVGW, TRGI,
TRF, VDE or all locally applicable
standards.
See also the safety instructions in the
Vitotec Technical Guide folder.
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of a
mains electrical isolator) and safe-
guard against unauthorised reconnec-
tion.
Close the main gas shut-off valve and
safeguard against unauthorised
reopening.
Electrical assemblies provided on site
must be type-approved.
Work on gas equipment
This must only be carried out by an
approved gas fitter.
Observe all commissioning work spe-
cified for gas installations to TRGI or
TRF and all local regulations.
Please observe all commissioning
work specified for gas systems.
Safety instructions
2
5862 570 GB

Preparing for installation
Product information .................................................................................... 4
Preparations for boiler installation............................................................... 4
Installation
Installing the boiler and making all connections ........................................... 6
&Wall mounting bracket installation ............................................................ 6
&Hanging the boiler into the wall mounting bracket ..................................... 7
Heating water (primary) connection............................................................. 8
Flue gas connection.................................................................................... 8
Condensate connection .............................................................................. 8
Gas connection .......................................................................................... 9
Opening the control unit housing................................................................. 10
Electrical connections................................................................................. 11
&Routing connecting cables....................................................................... 13
Closing control unit housing and inserting user interface ............................. 14
Front panel installation................................................................................ 15
Commissioning and adjustments................................................................. 15
Index
3
5862 570 GB

Vitodens 300, Type WB3A
Set up for operation with natural gas E or LPG P.
The natural gas E version can be converted to natural gas LL using a conver-
sion kit.
TheLPGPversioncanbeconvertedtonaturalgasEorLLusingaconversion
kit.
Preparations for boiler installation
AHeating flow G1½" BSafety valve
Product information
4
5862 570 GB

CDHW cylinder flow G1½"
DGas connection
EDHW cylinder return G1½"
FHeating return G1½"
GExpansion vessel
HCable arrangement area
KRecommended dimension
LCondensate drain
1. Prepare the water connections.
Thoroughly flush the heating sys-
tem.
2. Prepare the gas connection
accordingtoTRGIorTRForall
local regulations.
3. Prepare the electrical connections.
&Mainscable:NYM-J3x1.5mm
2
,
fuse max. 16 A, 230 V~, 50 Hz.
&Accessory cables: NYM with the
required number of conductors
for the external connections.
&All cables in area Hshould pro-
trude1200mmfromthewall.
Preparations for boiler installation (cont.)
5
5862 570 GB

Wall mounting bracket installation
Note
The enclosed screws and rawl plugs are only suitable for concrete. For other
construction materials, use fixings which are suitable for 110 kg loads.
AReference point: boiler top edge
BBoiler installation template
(included with the boiler)
CTopedgefinishedfloor
DRecommendation
Installing the boiler and making all connections
6
5862 570 GB

Hanging the boiler into the wall mounting bracket
Installing the boiler and making all connections (cont.)
7
5862 570 GB

AHeating flow
BDHW flow
CGas connection
DDHW return
EHeating return
FExpansion vessel
Connect the boiler to the on-site pipe-
work.
Flue gas connection
Connect the balanced flue pipe. Flue gas system installation
instructions
Condensate connection
Connect the condensate drain with a
pipe air vent valve sloping to the pub-
lic sewer.
Heating water (primary) connection
8
5862 570 GB

AGas connection
Conversion to other gas
types:
Conversion kit installation
instructions
Information regarding operation
with LPG
We recommend the installation of an
external safety solenoid valve when
installing the boiler in rooms below
ground level.
1. Carry out a leak test.
!Important information
Excessive test pressure
leadstodamagetotheboi-
ler and gas train.
Max. test pressure
150 mbar. If a higher pres-
sure is required for leak
tests, separate the boiler
and the gas train from the
mains gas supply (undo fit-
tings).
2. Purge the gas supply pipe.
Gas connection
9
5862 570 GB

Opening the control unit housing
10
5862 570 GB

Notes regarding the connection of accessories
For details of accessories, also observe the separate installation instruc-
tions provided.
ARadio clock connection
BHeating circuit pump or boiler cir-
cuit pump
Electrical connections
11
5862 570 GB

CVitotrol 100 UTD (only for control
units operating with a constant
temperature)
DVitotrol 100 UTA (only for control
units operating with a constant
temperature)
Plug 230 V~
fÖ Power supply
&Never interchange cores L1 and
N.
&Install an isolator in the mains
supply line which simulta-
neously separates all non-
earthed conductors from the
mains with at least 3 mm contact
separation.
&Max. fuse rating 16 A.
sÖ Heating circuit pump or boiler cir-
cuit pump
lH &Mains supply - accessories
(230 V ~ 50 Hz). Where the boi-
ler is installed in a bathroom or
shower room, the mains supply
of accessories outside the wet
area must not be connected to
the control unit. The power sup-
ply connection for accessories
canbemadeimmediatelyatthe
control unit, if the boiler is
installed outside damp areas.
This connection is directly con-
trolled with the system ON/OFF
switch (max. 4 A).
&Vitotrol 100 UTA
&Vitotrol 100 UTD
Low voltage plug
!Outside temperature sensor
(only for weather-compensated
mode)
Installation
&North or northwestern wall, 2
to2.5mabovegroundlevel.In
multi-storey buildings, in the
upper half of the second floor
&Not above windows, doors or
ventilation outlets
&Not immediately below balcony
or gutter
&Do not render over
&Twocorecablewithamaxi-
mum length of 35 m and a
cross-section of 1.5 mm
2
?Flow temperature sensor for low
loss header (accessories)
%Cylinder temperature sensor
(part of the DHW cylinder con-
nection set).
Connection to cables with plugs
outside of the control unit.
aVG KM BUS user (accessory)
&Vitotrol 200 or 300 remote con-
trol
&Vitocom 100
&Extension kit for one heating
circuit with mixer
&Vitosolic
&External extension H1 or H2
Electrical connections (cont.)
12
5862 570 GB

Routing connecting cables
!Important information
Connecting cables are damaged if they touch hot components.
When routing and securing connecting cables on site, ensure that the
maximum permissible cable temperatures are not exceeded.
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunications module
Electrical connections (cont.)
13
5862 570 GB

Closing control unit housing and inserting user interface
14
5862 570 GB

Commissioning and adjustments
For commissioning and adjustment, see service instructions.
Front panel installation
15
5862 570 GB

16
Printed on environmentally-friendly, chlorine-free bleached paper
5862 570 GB Subject to technical modifications
Viessmann Limited
Hortonwood 30, Telford, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
www.viessmann.co.uk

VIESMANN
Service instructions
for heating engineers
Vitodens 300
Type WB3A,49and66kW
Gas fired wall mounted condensing boiler
natural gas and LPG version
See applicability on the last page
VITODENS 300
5692 550 GB 5/2004 Please keep safe

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Important information
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the words "Note"
contain additional information.
Warranty
All warranty rights are void if these
service instructions are not observed.
Target group
These service instructions are exclu-
sively designed for qualified person-
nel.
Work on gas equipment must only be
carried out by a registered gas fitter.
Only approved contractors may mod-
ify this equipment for countries other
than those designated on the type
plate. That contractor will then
arrange for the relevant approval in
that country.
Electrical work must only be carried
out by a qualified electrician.
The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following during service
work:
&all legal instructions regarding the
prevention of accidents,
&the TRGI, TRF and special regula-
tions, e.g. those of the BDH,
&all legal instructions regarding
environmental protection,
&the Code of Practice by relevant
trade associations and all local reg-
ulations.
If you notice a smell of gas
Danger
Escaping gas can cause explo-
sionswhichmayleadtoser-
ious injury.
&Do not smoke. Prevent
naked flames and sparks.
Never switch electrical lights
or equipment.
&Open windows and doors.
&Close the gas shut-off valve.
&Remove all personnel from
the danger zone.
&Observe the safety regula-
tions of your local gas sup-
plier which can be found on
the gas meter.
&Notify your heating contrac-
tor from outside the building.
Safety instructions
2
Safety instructions
5692 550 GB

If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Repair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Service work on the heating system
&Isolate the system from mains sup-
ply, e.g. by removing a separate
fuse or by means of a mains electri-
cal isolator, and check that it is no
longer 'live'.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
Ancillary components, spare and
wearing parts
!Important information
Components which are not
tested with the heating system,
the installation of non-
approved spare parts and
unauthorised conversion may
lead to damage to the heating
system, which may affect their
function and limit our warranty.
For conversions or replace-
ments, use only original parts
from Viessmann or those which
are approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 550 GB

Initial start-up, inspection, maintenance
Steps - initial start-up, inspection and maintenance ..................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 38
Code 2........................................................................................................ 42
Resetting the coding to the delivered condition ........................................... 62
Service scans
Service level summary................................................................................ 63
Temperatures, boiler coding card and brief scans ....................................... 64
Checking outputs (relay test) ...................................................................... 68
Scanning operating conditions and sensors ................................................ 70
Troubleshooting
Calling up fault code history ........................................................................ 73
Call up current fault codes .......................................................................... 73
Checking and acknowledging faults ............................................................ 75
Repairs ...................................................................................................... 85
Function description
Constant temperature control units ............................................................. 95
Weather-compensated control units............................................................ 96
Extensions for external connections (accessory)......................................... 98
Control functions ........................................................................................ 102
Designs
Connection and wiring diagrams –internal connections .............................. 107
Connection and wiring diagrams –external connections.............................. 109
Parts lists .................................................................................................. 111
Commissioning/service reports............................................................... 118
Specification............................................................................................. 124
Certificates
Declaration of conformity ............................................................................ 125
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 126
Keyword index .......................................................................................... 127
Index
4
Index
5692 550 GB