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