Viessmann Vitodens 300 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 300
Type WB3A, 4.2 to 13.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 300
5692 569 GB 1/2005 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.
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Warranty
Non-observation of our service
instructions will void all warranty
rights.
Target group
These service instructions are exclu-
sively designed for qualified person-
nel.
Work on gas appliances must only be
carried out by a qualified gas fitter.
Only recognised contractors may con-
vert this boiler for use in countries
other than those stated on the type
plate. That contractor must also
arrange the acceptance in accor-
dance with the statutes of that coun-
try.
Work on electrical equipment must
only be carried out by a qualified elec-
trician.
The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when servicing
the equipment:
&all legal instructions regarding the
prevention of accidents,
&the TRGI, TRF and any special
requirements, or local regulations
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations.
If you smell gas
Danger
Escaping gas can lead to
explosions which may lead to
serious injury.
&Never smoke. Prevent naked
flames and sparks.
&Never switch lights or electri-
cal appliances ON or OFF.
&Open windows and doors.
&Close the gas shut-off valve.
&Remove all people from the
danger zone.
&Observe the safety regula-
tions of your local gas sup-
plier, found on the gas meter.
&Notify your contractor from
outside the building.
Safety instructions
2
Safety instructions
5692 569 GB

If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close doors to the living
space.
Repair work
on parts that fulfil a safety function is
not permitted.
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 the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&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
!Please note
Components which are not
tested with the heating system,
the installation of non-
approved spare parts and un-
authorised conversions may
lead to damage on the heating
system, or may affect its func-
tion and void all warranties.
For conversions or replace-
ments, use only original spare
parts supplied or approved by
Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 569 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 39
Code 2........................................................................................................ 42
Resetting codes to the delivered condition ................................................. 61
Service scans
Service level overview ................................................................................ 63
Temperatures, boiler coding card and brief scans ....................................... 63
Checking outputs (relay test) ...................................................................... 67
Scanning operating conditions and sensors ................................................ 69
Troubleshooting
Fault display ............................................................................................... 72
Calling up fault codes from the fault memory (fault history) .......................... 73
Fault codes................................................................................................. 74
Repairs ...................................................................................................... 83
Function description
Constant temperature control unit ............................................................... 93
Weather–compensated control unit............................................................. 94
Extensions for external connections (accessories) ...................................... 96
Control functions ........................................................................................ 100
Electronic combustion control unit............................................................... 105
Designs
Connection and wiring diagrams –internal connections .............................. 106
Connection and wiring diagrams –external connections.............................. 107
Parts lists .................................................................................................. 109
Specification............................................................................................. 122
Certificates
Declaration of conformity ............................................................................ 123
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 124
Keyword index .......................................................................................... 125
Index
4
Index
5692 569 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler .................................................................. 8
•03. Venting the heating system............................................... 8
•04. Filling the siphon with water............................................. 9
•05. Checking the power supply connection
•06. Selecting the language (if required) - only for
weather-compensated control units ............................. 9
• • 07. Setting the time and date (if required) –only for
weather-compensated control units ............................. 10
• • 08. Checking the gas type......................................................... 10
•09. Changing the gas type (only for operation with
LPG) ........................................................................................... 11
••• 10. Function sequence and possible faults ....................... 11
••• 11. Checking the static and supply pressure .................... 13
••• 12. Checking the combustion quality................................... 15
•13. Setting the maximum output ........................................... 16
••• 14. Checking all connections on the primary and DHW
side for leaks
••• 15. Checking the burner (recording values on page
116 of the commissioning report)
•16. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 17
• • 17. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 18
• • 18. Checking the burner gauze assembly........................... 19
• • 19. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 20
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 569 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Cleaning the combustion chamber/heating
surfaces and fitting the burner ........................................ 21
• • 21. Checking the condensate drain and cleaning the
siphon........................................................................................ 22
• • 22. Checking the neutralising system (if installed)
• • 23. Checking the diaphragm expansion vessel and
system pressure.................................................................... 22
••• 24. Checking the function of all safety valves
••• 25. Checking the tightness of electrical connections
••• 26. Checking all gas equipment for soundness at
operating pressure .............................................................. 23
••• 27. Checking the ionisation current ..................................... 24
••• 28. Checking external LPG safety valve (if required)
•29. Matching the control unit to the heating system ...... 25
•30. Connecting the weather-compensated control unit
into the LON system (e.g. with the Vitotronic 050) . . . 31
•31. Implementing a user check (in conjunction with
the LON system) .................................................................... 32
•32. Adjusting the heating curve (only for weather-
compensated control units).............................................. 33
•33. Instructing the system user .............................................. 37
•34. Scanning and resetting the "Maintenance" display 37
Steps –initial start-up, inspection and . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 569 GB

Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water harder than 3.58 mmol/l.
&An anti-freeze additive suitable for heating systems can be mixed with
the fill water.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Drain the heating system via boiler
fill & drain valve A(minimum sys-
tem pressure >0.8 bar).
Note
&If the control unit had not already
been switched ON before filling
began: The diverter valve is in its
central position, and the system
will be completely filled.
&If the control unit had already
been switched ON before filling
began: In code 1, set coding
address "2F:2" (see page 39).
&At this point, the diverter valve is
in its central position.
&Whilst the filling program runs,
the display shows "bF" (constant
temperature control unit) or
"Filling" (weather-compensated
control unit).
4. Close boiler fill & drain valve A.
5. Set coding address "2F:0".
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 569 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose between
top valve Band a drain outlet.
3. Open valves Aand B, and vent
at mains pressure until no sound of
escaping air can be heard.
4. Close valves Aand Band open
the primary shut-off valves.
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 569 GB

2. Activate the venting program via
coding address "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 39.
For function and sequence of the
venting program, see page 101.
Whilst the venting program runs,
the display shows "EL" (constant
temperature control unit) or
"Venting" (weather-compensated
control unit).
3. Check the system pressure.
Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fill the siphon with water.
3. Fit siphon Aand secure with the
retaining clip.
Selecting the language (if required) - only for weather-com-
pensated control units
1. Press c.
The display shows "Select heating
circuit".
2. Press d.
3. After approx. 4 s press c.
4. Select the required language with
b.
5. Confirm with d.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 569 GB

Setting the time and date (if required) –only for weather-
compensated control units
Note
During commissioning, or after prolonged time out of use, it may be necessary
to set the time and date, if the time flashes in the display.
1. Set the correct time with a/b.
2. Confirm with d.
3. Set the current date with a/b.
4. Confirm with d.
Checking the gas type
The boiler is equipped with an electronic combustion control unit, which adjusts
the burner for optimum combustion in accordance with the prevailing gas qual-
ity.
&For natural gas, there is consequently no adjustment required across the
entire Wobbe range.
&The boiler can be operated in the Wobbe index range 10.0 to 16.1 kWh/m
3
(36.0 to 58.0 MJ/m
3
).
&The burner must be adjusted for operation with LPG (see "Changing the gas
type" on page 11).
1. Determine the gas type and Wobbe
index (Wo) by asking your local
mains gas or LPG supplier.
2. Convert the burner for operation
with LPG (see page 10).
3. Record the gas type in the service
report on page 116.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 569 GB

Changing the gas type (only for operation with LPG)
1. Turn adjusting screw A(Allen
screw 2.5 mm) on the gas combina-
tion valve clockwise as far as possi-
ble towards "–" (approx. 30 turns).
2. Switch ON the system ON/OFF
switch "8".
3. Adjust the gas type in coding
address "82" (for a detailed
description of the individual steps,
see page 91):
&Call up code 2
&In coding address "11", select
value "9"
&In coding address "82", select
value "1" (operation with LPG)
&Set code "11" ≠"9" and terminate
code 2.
4. Open the gas shut-off valve.
Function sequence and possible faults
For further details regarding faults, see page 74.
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Yes
Fan starts No after approx. 51 s Check fan cables
and plugs
Fault
F9
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 569 GB

Yes
Ignition No Fault Check ignition
module (control
voltage 230 V
across plugs
"X2.1" and "X2.2"
F4
Yes
Gas combination
valve opens No Fault Check the gas
combination valve
(control voltage
230 V); check the
gas supply pres-
sure
F4
Yes
Ionisation cur-
rent builds
(higher than
5 µA) No
Fault Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks.
Symbol AF4
Yes
Burner in opera-
tion
Stops below set
boiler water tem-
perature and re-
starts
Check flue gas
system for sound-
ness (flue gas re-
circulation),
check gas flow
pressure
Yes
Automatic cali-
bration of the
combustion con-
trol unit
No Fault Check the electri-
cal connecting
cable and the io-
nisation electrode
EB
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 569 GB

Checking the static and supply pressure
Danger
Higher CO emissions can lead to poisoning.
Check the CO emissions before and after any work on gas appliances, to
prevent any health hazards and to ensure the perfect operational condi-
tion of the system.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas lines after flushing.
1. Close the gas shut-off valve.
2. Release the screw inside the test
port "PE"Aat the gas combination
valve, but do not remove it, and
connect the pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure; it should
be a max. of 57.5 mbar. Record the
actual value in the service report.
5. Start up the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 s, press "E" to reset the
burner.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 569 GB

6. Check the supply (flow) pressure; it
should be
&for natural gas 20 mbar,
&for LPG 50 mbar.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
test the supply pressure.
Record the actual value in the ser-
vice report.
Take the action shown in the table.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Remedy
below 17.4 mbar below 42.5 mbar Never start up the boiler. Notify your
mains gas or LPG supplier.
17.4 to 57.5 mbar 42.5 to
57.5 mbar
Start up the boiler.
in excess of
57.5 mbar
in excess of
57.5 mbar
Install a separate gas governor down-
stream of the system and regulate the
pressure to 20 mbar for natural gas or
50 mbar for LPG. Notify your mains gas
or LPG supplier.
7. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test port Awith
the screw.
8. Danger
Gas escaping from the test
port leads to a risk of explo-
sion.
Check for soundness.
Open the gas shut-off valve, start
the boiler and check the soundness
of test port A.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 569 GB

Checking the combustion quality
The electronic combustion control unit automatically ensures an optimum com-
bustion quality. Only the combustion values need to be checked during commis-
sioning and maintenance. For this, check the CO2or O2content. For a function
description of the electronic combustion control unit, see page 105.
CO2or O2content
The CO2content must be within the following ranges (upper and lower output):
&7.7 to 9.2% for natural gas E and LL
&9.3 to 10.9% for LPG P
For all gas types, the O2content must be between 4.4% and 6.9%.
If the actual CO2or O2value lies outside the respective range, proceed with the
following steps:
&Check the balanced flue system for soundness, see page 17.
&Check the ionisation electrode and connecting lead, see page 20.
&Check the parameters of the combustion control unit, see page 91.
Note
During commissioning, the combustion control unit carries out an automatic
calibration. This may lead to CO emissions in excess of 1000 ppm for a short
time.
1. Connect a flue gas analyser at flue
gas port Aon the flue outlet.
2. Open the gas shut-off valve, start
the boiler and create a heat
demand.
3. Adjust the lower output.
Constant temperature control unit:
&Press both keys 9and dsimul-
taneously, until the display shows
"1".
Weather-compensated control unit:
&Press both keys 9and dsimul-
taneously until the display shows
"Relay test".
&With a/bin the display, select
"Base load".
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 569 GB

4. Check the CO2content. Should the
actual value deviate by more than
1% from the above range, imple-
ment the steps from page 15 (pos-
sibly replace the burner).
5. Enter actual values into the service
report.
6. Adjust the upper output.
Constant temperature control unit:
&With a/bin the display, select
"2".
Weather–compensated control unit:
&With a/bin the display, select
"Full load".
7. Check the CO2content. Should the
actual value deviate by more than
1% from the above range, imple-
ment the steps from page 15 (pos-
sibly replace the burner).
8. After testing, press d.
9. Enter actual values into the service
report.
Setting the maximum output
Note
The maximum output can be limited for heating operation. You can limit the
output via the modulation range.
1. Start up the boiler.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 569 GB

2. Press both Kand Fsimulta-
neously until "100" flashes on the
display, (equals 100% of the rated
output) and "A" appears. On
weather-compensated control
units, the display additionally
shows "Max. output".
3. With a/bselect the required
value in % of rated output as maxi-
mum output.
4. Confirm the set value with d.
5. Record the settings for maximum
output on the additional type plate
included with the "technical docu-
mentation". Affix the type plate next
to the original type plate on top of
the boiler.
Note
The output can also be limited for
DHW heating. For this, change coding
address "6F" in code 2.
Checking the balanced flue system for soundness (annular
gap check)
ACombustion air aperture
For balanced flue systems tested
together with the wall mounted gas
fired boiler, some authorities waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
We recommend that your heating
engineer carries out a simple leak test
during the commissioning of your sys-
tem. For this it would be sufficient to
check the CO2concentration in the
combustion air at the annular gap of
the balanced flue pipe.
The flue pipe is deemed to be sound if
the CO2concentration in the combus-
tion air is no higher than 0.2% or the
O2concentration is at least 20.6%.
If actual CO2values are higher or O2
values are lower, then pressure test
the flue pipe at a static pressure of
200 Pa.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 569 GB

Removing the burner and checking the burner gasket
(replace gasket every two years)
1. Switch OFF the control unit ON/
OFF switch and the power supply.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull electrical cables off fan motor
A, gas valve B, ionisation elec-
trode C, ignition unit Dand earth
connector E.
4. Undo the fixing screws of gas sup-
ply flange F.
5. Release four nuts Gand remove
the burner.
!Please note
Prevent damage to the wire
gauze.
Never rest the burner on the
gauze assembly.
6. Check the burner gasket Hfor
damage.
Generally replace the burner gas-
ket every 2 years.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 569 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if
the wire gauze is damaged.
1. Remove electrodes A.
2. Release the three nuts Band
remove the burner gauze assembly
C.
3. Remove the old burner gauze gas-
ket D.
4. Insert a new burner gauze assem-
bly with a new gasket and secure
with three nuts.
Note
Torque: 4 Nm
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 569 GB

Checking and adjusting the ignition and ionisation electro-
des
AIgnition electrodes BIonisation electrode
1. Check the electrodes for wear and
contamination.
2. Clean the electrodes with a small
brush (not with a wire brush) or
emery paper.
!Please note
Never damage the wire
gauze.
3. Check clearances. If the gaps are
not as specified or the electrodes
are damaged, replace and align the
electrodes together with new gas-
ket A. Tighten the electrode fixing
screws with 2 Nm.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 569 GB