Viessmann Vitodens 300 Operating instructions

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

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.................................................................. 8
•3. Venting the heating system............................................... 8
•4. Filling the siphon with water............................................. 9
•5. Checking the electrical mains connection
•6. Language selection (if required) - only for the
weather-compensated control units.............................. 9
•• 7. Setting the time and date (if required) - only for
weather-compensated control units.............................. 9
••8. Checking the gas type......................................................... 10
•9. Changing the gas type (see separate installation
instructions)
••• 10. Function sequence and possible faults ....................... 10
••• 11. Checking static and supply pressure ........................... 12
••• 12. Checking the CO2settings ................................................ 14
•13. Setting the max. output ...................................................... 16
••• 14. Checking all connections on the primary and DHW
side for leaks
••• 15. Checking the burner (recording values on
page 118 of 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 ................................................................................ 19
Steps - initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 550 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 20. Cleaning the combustion chamber/heating
surfaces and installing 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
••• 24. Checking the function of all safety valves
••• 25. Checking tightness of electrical connections
••• 26. Checking all gas equipment for soundness at
operating pressure............................................................... 22
••• 27. Checking the ionisation current...................................... 23
••• 28. Checking the external LPG safety valve (if
installed)
•29. Matching the control unit to the heating system....... 24
•30. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 31
•31. Implementing a user check (in conjunction with
the LON system) .................................................................... 32
•32. Adjusting heating curves (only for weather-
compensated control units).............................................. 33
•33. Instructing the system user .............................................. 36
•34. Scanning and resetting the "Maintenance" display 37
Steps - initial start-up, inspection and maintenanc . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 550 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 depos-
its and corrosion and may
lead to boiler damage.
&Thoroughly flush the entire
heating system prior to fill-
ing with water.
&Only use fill water of pota-
ble quality.
&Soften fill water harder
than 20 °dH (3.58 mmol/l).
For suitable means of
water softening, see the
Vitotec pricelist.
&An anti-freeze additive sui-
table for heating systems
canbemixedwiththefill
water.
Fill the heating system via the boi-
ler fill & drain valve A(minimum
system pressure > 0.8 bar).
4. Close the boiler fill & drain
valve A.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 550 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose to the boiler
fill & drain valve B.
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.
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 38.
For function and sequence of the
venting program, see page 103.
3. Check the system pressure.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 550 GB

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.
2. Select the required language
with b.
3. Confirm with d.
Setting the time and date (if required) - only for weather-com-
pensated control units
Note
During commissioning, or after prolonged time out of use, it may be necessary
to set the time and date.
1. Press D.
2. Set the correct time with a/b.
3. Confirm with d;Date will then be
displayed.
4. Set the current date with a/b.
5. Confirm with d.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 550 GB

Checking the gas type
!Important information
The natural gas version cannot be
converted to LPG.
1. Enquire about the gas type and
Wobbe index (Wo) from your local
mains gas or LPG supplier.
Note
In the delivered condition, Vito-
dens 300 is set up for natural gas E
or LPG P.
Natural gas E version:
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m
3
(43.2to58.0MJ/m
3
).
LPG P version:
The boiler can be operated in the
Wobbe index range 21.4 to
22.5 kWh/m
3
(76.9to81.0MJ/m
3
).
2. Compare the gas category (gas
type) and gas group with the details
on the label on the gas train and
the cap plate.
3. If these details do not match the
fuel provided, the burner must be
convertedaccordingtothedetails
provided by the mains gas or the
LPG supplier.
Seeseparateconversionkit
installation instructions.
After conversion from
&NaturalgasEorLPGPtonat-
ural gas LL
The boiler can be operated in the
Wobbe index range 10.0 to
13.1 kWh/m
3
(36.0to47.2MJ/
m
3
).
&LPG P to natural gas E
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m
3
(43.2to58.0MJ/
m
3
).
4. Set the gas type via coding
address 1E at the control unit.
Note
To call up code 1 and for setting the
coding address, see page 38.
5. Record the gas type in the service
report on page 118.
Function sequence and possible faults
For further details regarding faults, see page 75.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 550 GB

Display screen Remedy
Control unit
issues heat
demand
No Set value
Yes
Fan starts
No
After approx.
51 seconds
Check cables and
plug-in connec-
tions
Fault
F9
Yes
Differential pres-
sure sensor
enables start
(0.75 V across
terminals X8.5
and X8.6)
No
After approx.
51 seconds
Check fan cables
and fan plug-in
connections,
check fan
Fault
E6
Yes
Ignition No Fault Check the ignition
module (control
voltage 230 V
across plugs X2.1
and X2.2)
F4
Yes
Gas combination
valve opens No Fault Check the gas
train (control vol-
tage 230 V) and
gassupplypres-
sure
F4
Yes
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 550 GB

Ionisation cur-
rent builds
(higher than
5µA) No
Fault Check electrode
adjustment and
gas pipe for air-
locks
Symbol AF4
Yes
Operational bur-
ner
Stops below set
boiler tempera-
ture and restarts
Check flue gas
system for sound-
ness (flue gas
recirculation),
check gas flow
pressure
Checking static and supply pressure
Danger
Higher CO emissions can lead to poisoning.
Measure the CO value before and after any work on gas equipment 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.
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 550 GB

1. Close the gas shut-off valve.
2. Release the screw inside test nip-
ple PE Aon the gas combination
valve , but do not remove, and con-
nect 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 boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 seconds, press Eto
reset the burner.
6. Check the supply (flow) pressure; it
should be
&20 mbar for natural gas,
&50 mbar for LPG.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
Record the actual value in the ser-
vice report.
Taketheactionshowninthetable.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 550 GB

Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Remedy
Below 17.4 mbar Below 42.5 mbar Do not start up. Notify your mains gas or
LPG supplier.
17.4 to 57.5 mbar 42.5 to
57.5 mbar
Start up boiler.
Above 57.5 mbar Above 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 nipple A
with the screw.
8. Open the gas shut-off valve and
start the boiler.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check test nipple Afor
soundness.
Checking the CO2settings
Vitodens 300 is factory-set for natural gas E or LPG P. The natural gas E version
can be converted to natural gas LL using a conversion kit. The LPG P version
canbeconvertedtonaturalgasEorLLusingaconversionkit.
During commissioning or maintenance, check the CO2level at the boiler adap-
tor.
Note
The MatriX burner for Vitodens 300 is preset for the entire gas group. Therefore,
the burner requires no further setting or adjustment.
Subject to the Wobbe index, the CO2content fluctuates between
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 550 GB

&6.6 to 10.0 % for natural gas E
&7.0 to 10.0 % for natural gas LL and
&approx. 10.0 % for LPG P.
Compare the actual CO2value with the above CO2value ranges for the indivi-
dual gas groups (check the gas group with your mains gas or LPG supplier).
If the actual CO2value deviates by more than 1 % for natural gas or 0.5 % for
LPG, proceed as follows:
&Check whether the correct gas restrictor has been installed.
&Check the balanced flue system for soundness, see page 17.
1. Connect a flue gas analyser at the
flue gas aperture Aon the boiler
adaptor.
2. Open the gas shut-off valve, com-
mission the boiler and create a heat
demand.
3. Select the lower rated output.
Constant temperature control units:
&Press both keys 9and dsimul-
taneously, until the display shows
1.
Weather-compensated control
units:
&Press both keys 9and dsimul-
taneously until the display shows
"Relay test".
&With a/bin the display, select
"Basic load".
4. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 15 (possibly
replace the burner).
5. Enter actual values into the service
report.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 550 GB

6. Set the upper rated output.
Constant temperature control units:
&With a/bin the display, select
2.
Weather-compensated control
units:
&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 steps from page 15 (possibly
replace the burner).
8. After testing, press d.
9. Enter actual values into the service
report.
Setting the max. output
Note
The max. output can be limited for heating operation. You can limit the output
via the modulation range.
1. Start up boiler.
2. Press both Kand Fsimulta-
neously until 100 flashes on the
display, (equals 100 % of the rated
output) and Aappears. On
weather-compensated control
units, the display additionally
shows "Max. output".
3. With a/bselect the required
value in % of rated output as max.
output.
4. Confirm the set value with d.
5. Record the settings for max. 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
Theoutputcanalsobelimitedfor
DHW loading. For this, change coding
address 6F in code 2.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 550 GB

Checking the balanced flue system for soundness (annular
gap check)
ACombustion air aperture
For balanced flue systems tested
together with the gas fired wall
mounted boiler, some Federal States
(e.g. Northrhein-Westphalia) waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
For such cases we recommend that
your heating contractor carries out a
simple soundness test during the
initial start-up of your system. For
this, it would be sufficient to check the
CO2concentration in the combustion
air at the annular gap in the balanced
flue pipe.
Thefluepipeisdeemedtobesound,
if the CO2concentration of the com-
bustion 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, carry out a pressure
testonthefluepipeatastaticpres-
sure of 200 Pa.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 550 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 mains electrical
supply.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull electrical cables from fan
motor A, differential pressure sen-
sor B,gasvalveC, ionisation
electrode D, ignition electrodes
Eand earth F.
4. Release gas connection pipe G
fixing screws and fittings.
5. Release six nuts Hand remove
the burner.
!Important information
Prevent damage to the wire
mesh.
Never rest the burner on the
gauze assembly.
6. Check the burner gasket (see parts
list) for damage.
Generally, replace the burner gas-
ket every two years.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 550 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if the wire mesh is damaged.
1. Remove electrodes A.
2. Turn thermal insulation ring B
clockwise and remove.
3. Release the eight Torx screws C
and remove the burner gauze
assembly D.
4. Remove the old gauze assembly
gasket E.
5. Insert a new burner gauze assem-
bly with a new gasket, and secure
with eight Torx screws.
Note
Torque: 4.5 Nm
6. Refit the thermal insulation ring B.
Checking and adjusting the ignition and ionisation electro-
des
AIonisation electrode BIgnition electrodes
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 550 GB

1. Check the electrodes for wear and
contamination.
2. Clean the electrodes with a small
brush (not with a wire brush) or
emery paper.
!Important information
Wire mesh
do not damage.
3. Check all clearances. If the gaps
are not as specified or the electro-
des are damaged, replace and
align the electrodes together with
new gaskets. Tighten the electrode
fixing screws with 2 Nm.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 550 GB