Viessmann Vitodens 300 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 300
Type WB3A, 6.6 to 35.0 kW
Gas fired wall mounted condensing boiler
natural gas and LPG version
See applicability on the last page
VITODENS 300
5692 537 GB 6/2004 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.
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.
&Electrical work must only be carried
out by a qualified electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following during service
work:
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice by relevant
trade associations and all local reg-
ulations.
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
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.
&Shut down the system.
&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.
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.
Safety instructions
2
Safety instructions
5692 537 GB

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.
Repair work
!Important information
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
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 spare
parts from Viessmann or those
which are approved by Viess-
mann.
Safety instructions (cont.)
3
Safety instructions
5692 537 GB

Initial start-up, inspection, maintenance
Steps - initial start-up, inspection and maintenance ..................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 40
Code 2........................................................................................................ 43
Resetting the coding to the delivered condition ........................................... 63
Service scans
Service level summary................................................................................ 64
Temperatures, boiler coding card and brief scans ....................................... 65
Checking outputs (relay test) ...................................................................... 69
Scanning operating conditions and sensors ................................................ 71
Troubleshooting
Calling up fault code history ........................................................................ 74
Calling up current fault codes...................................................................... 74
Checking and acknowledging faults ............................................................ 76
Repairs ...................................................................................................... 85
Function description
Constant temperature control units ............................................................. 96
Weather-compensated control units ............................................................ 98
Extensions for external connections (accessory)......................................... 100
Control functions ........................................................................................ 104
Designs
Connection and wiring diagrams –internal connections............................... 109
Connection and wiring diagrams –external connections.............................. 111
Parts lists .................................................................................................. 113
Commissioning/service reports............................................................... 120
Specification............................................................................................. 126
Certificates
Declaration of conformity ............................................................................ 127
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 128
Keyword index .......................................................................................... 129
Index
4
Index
5692 537 GB

For further instructions on individual steps, see pages indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•1. Filling the heating system ................................................. 7
•2. Venting the boiler.................................................................. 9
•3. Venting the heating system............................................... 10
•4. Filling the siphon with water............................................. 10
•5. Checking the electrical mains connection
•6. Language selection (if required) - only for the
weather-compensated control units.............................. 10
•• 7. Set the time and date (if required) - only for
weather-compensated control units.............................. 11
••8. Checking the gas type......................................................... 11
•9. Gas type conversion............................................................ 12
••• 10. Function sequence and possible faults ....................... 12
••• 11. Checking static and supply pressure ........................... 14
••• 12. Checking the CO2settings ................................................ 16
•13. Setting the max. output ...................................................... 18
••• 14. Checking all connections on the primary and DHW
side for leaks
••• 15. Checking the burner (recording values on
page 120 of commissioning report)
•16. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 19
•• 17. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 20
•• 18. Checking the burner gauze assembly........................... 21
•• 19. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 22
•• 20. Cleaning the combustion chamber/heating
surfaces and installing the burner ................................. 23
Steps - initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 537 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 21. Checking the condensate drain and cleaning the
siphon........................................................................................ 24
•• 22. Checking the neutralising system (if installed)
•23. Flow limiter (only for gas combination boilers)......... 25
••• 24. Checking the diaphragm expansion vessel and
system pressure
••• 25. Checking the function of all safety valves
••• 26. Checking tightness of electrical connections
••• 27. Checking all gas equipment for soundness at
operating pressure............................................................... 25
••• 28. Checking the ionisation current ..................................... 26
••• 29. Checking the external LPG safety valve (if
installed)
•30. Matching the control unit to the heating system....... 27
•31. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 33
•32. Implementing a user check (in conjunction with
the LON system) .................................................................... 34
•33. Adjusting heating curves (only for weather-
compensated control units).............................................. 35
•34. Instructing the system user .............................................. 39
•35. Scanning and resetting the "Maintenance" display 39
Steps - initial start-up, inspection and maintenanc . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 537 GB

Filling the heating system
1. Check the charge pressure of the
diaphragm expansion vessel.
2. Close the gas shut-off valve.
3. !Important information
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 with water.
&Only use fill water of pota-
ble quality.
&Soften fill water harder
than 20 °dH (3.58 mmol/l).
&An anti-freeze additive
suitable for heating sys-
temscanbemixedwith
the fill water.
Fill the heating system via the boi-
ler fill & drain valve A.(minimum
system pressure > 0.8 bar).
Note
The diverter valve actuator will be
in the central position, and the sys-
tem will be completely filled, if the
control unit has not been switched
ON before the system was filled.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 537 GB

4. If the control unit had already been
switched ON before filling began:
Start the control unit and in code 1,
set coding address 2F:2.
The diverter valve will then be in its
central position.
Note
To call up code 1 and for setting the
coding address, see page 40.
Whilst filling is in progress, the dis-
play shows bF (constant tempera-
ture control units) or "Filling"
(weather-compensated control
units).
Continue filling the system.
5. Close the boiler fill & drain valve
A.
6. Set coding address 2F:0.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 537 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose on the
upper valve Bwithadrainoutlet.
3. Open valves Aand B,andvent
at mains pressure, until no sound of
escaping air can be heard.
4. Close valves Aand B, and open
the primary shut-off valves.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 537 GB

Venting the heating system
1. Close the gas shut-off valve and
start the control unit.
2. Activate the venting program via
coding address 2F:1.
Note
To call up code 1 and for setting the
coding address, see page 40.
For function and sequence of the
venting program, see page 105.
Whilst venting is in progress, the
display shows EL (constant tem-
perature control units) or "Venting"
(weather-compensated control
units).
3. Check the system pressure.
Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fillthesiphonwithwater.
3. Fit siphon Aandsecurewiththe
retaining clip.
Language selection (if required) - only for the weather-com-
pensated control units
1. Press c.
The display shows "Select heating
circuit".
2. Press d.
3. After approx. 4 seconds, press c.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 537 GB