Viessmann Vitotwin 300-W Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitotwin 300-W
Type C3HA
Micro CHP boiler based on Stirling engine
Natural gas version
For applicability, see the last page
VITOTWIN 300-W
5618 294 GB 4/2012 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ 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 working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5618 294 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5618 294 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 6
Installation sequence
Fitting the wall mounting bracket.......................................................................... 36
Mounting the boiler............................................................................................... 38
Removing the front panel..................................................................................... 39
Removing the transport brackets......................................................................... 42
Filling the siphon with water................................................................................. 43
Flue outlet............................................................................................................. 44
Condensate connection........................................................................................ 44
Gas connection.................................................................................................... 45
Opening the control unit casing............................................................................ 47
Terminal connections........................................................................................... 47
Mounting the front panel....................................................................................... 58
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 59
Further details regarding the individual steps....................................................... 61
Codes
Calling up codes................................................................................................... 85
Changing codes................................................................................................... 86
Service scans
Calling up service scans....................................................................................... 112
Fault messages and fault history.......................................................................... 112
Status (operating states)...................................................................................... 112
Relay test............................................................................................................. 113
Input/output test.................................................................................................... 114
Service/special operation (service functions)....................................................... 115
Diagnostics........................................................................................................... 116
Troubleshooting
Fault display......................................................................................................... 121
Implementing a user reset ................................................................................... 121
Carry out service reset ........................................................................................ 122
Reset circuit breaker............................................................................................ 122
Fault messages.................................................................................................... 123
Index
Index
5618 294 GB

5
Repairs................................................................................................................. 138
Function description
Boiler temperature control.................................................................................... 153
Cylinder temperature control................................................................................ 156
Heating circuit control........................................................................................... 158
Designs
Connection and wiring scheme............................................................................ 161
Parts lists
Ordering parts...................................................................................................... 165
Overview of the assemblies................................................................................. 166
Sheet metal parts assembly................................................................................. 167
Heat cell assembly............................................................................................... 169
Heat exchanger assembly.................................................................................... 171
Burner assembly.................................................................................................. 171
Air distribution valve assembly............................................................................. 172
Gas:air route assembly........................................................................................ 174
Stirling unit assembly........................................................................................... 176
Hydraulic assembly.............................................................................................. 178
Control unit assembly........................................................................................... 180
Miscellaneous assembly...................................................................................... 182
Commissioning/service reports
Report................................................................................................................... 184
Specification....................................................................................................... 186
Certificates
Declaration of conformity...................................................................................... 187
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 188
Keyword index.................................................................................................... 189
Index
Index (cont.)
5618 294 GB

6
Vitotwin 300-W, C3HA
Preset for operation with natural gas E.
Conversion to natural gas LL see page 66.
Rated heating output range (TV/TR 40/30 °C) 3.5 to 26.0 kW.
Electrical output max. 1 kW (gross).
The integral net electricity meter is approved to DIN VDE AR 4105.
Destination countries
As a general rule, the Vitotwin 300-W may only be supplied to those countries speci-
fied on the type plate. For deliveries to alternative countries, an approved contractor
must arrange individual approval on his own initiative and in accordance with the law
of the country in question.
Preparing for installation
Transportation and handling
!Please note
To avoid equipment damage,
move the Vitotwin 300-W
on its pallet to the installation
location.
Transport the appliance in a ver-
tical position wherever possible.
The appliance may be placed in
a horizontal position for up to
30 min during handling.
Power supply
!Please note
To avoid equipment damage,
never operate the Vitotwin 300-W
with anything other than mains
power.
Preparing for installation
Product information
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7
Information regarding system versions
■ The Vitotwin 300-W will be delivered
with connection accessories for the
relevant system version in accordance
with the order.
■ Connect the DHW circulation pump on
site (if applicable).
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

8
System version 1, ID: 4605451_1201_02
System with multi mode heating water buffer cylinder
Hydraulic installation scheme
2 B
--2B/ATS--
--230V--
--52-- --20-- --2--
kW
21
5
22
20
--2B/B4--
--2B/B3--
8
6
1
--B42--
--B4--
--B3--
--ATS--
41
-Wireless-
4
--B41-- --2B/WIRELESS--
HV1
WW/Z
HV2/HR1
HVS/HRS
E
kW
HR3
HR2
--2B/B41--
3 A
3 B
40
42
44
--41/2--
--41/52--
--41/20--
43
--2B/B42--
7
--BSB--
--X1--
2
--230V-- --X300--
--X301--
--X207--
--BSB--
HV1 N/A WW/Z DHW/DHW circulation
Preparing for installation
Preparing for installation (cont.)
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9
HV2/HR1 Heating water flow,
Vitotwin 300-W
HR2 Heating water flow, heating
circuit
HR3 Heating water return, heat-
ing circuit
KW Cold water
E Drain
HVS/HRS Heating water return,
Vitotwin 300-W
Equipment required
Pos. Designation
1Vitotwin 300 W
with
2Weather-compensated control unit
2BJunction box for sensors and accessories (low voltage)
3ARemote control unit FBE
3BWireless base station FB
4Outside temperature sensor ATS
5Cylinder temperature sensor STS B3
6Buffer temperature sensor PTSO B4, top
7Sensor for power demand function B41
8Buffer temperature sensor PTSU B42, bottom
DHW heating
wP Multi mode heating water buffer cylinder with integral DHW heating
Vitocell 340-M
wQ DHW circulation pump CP (electrical connection on site)
wW Automatic thermostatic mixing valve
rP Heating circuit 1 with mixer
rQ Extension kit for one heating circuit with mixer with integral mixer motor
and
rW Flow temperature sensor heating circuit M1
rE Heating circuit pump, heating circuit M1
rR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
tP Heating circuit 2 with mixer
tQ Extension kit for one heating circuit with mixer with integral mixer motor
and
tW Flow temperature sensor, heating circuit M2
tE Heating circuit pump, heating circuit M2
tR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

10
Pos. Designation
zP Heating circuit 3 with mixer (and plate heat exchanger for system sep-
aration)
zQ Extension kit for one heating circuit with mixer with integral mixer motor
and
zW Flow temperature sensor, heating circuit M3
zE Heating circuit pump, heating circuit M3
zR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
zZ Plate heat exchanger for system separation
Accessories (optional)
uP Vitocom 100, type GSM
uQ Central fault message
no pos.
no.
Wireless repeater for wireless remote control
no pos.
no.
230 V∼ extension
Installation of the Vitotwin 300-W with
the supplied installation aid:
Installation aid installation
instructions
Preparing for installation
Preparing for installation (cont.)
5618 294 GB

11
Connections on the multi mode heat-
ing water buffer cylinder
D
E
H
B
FG
L
K
MN
A
P
C
O
Connection assignment in conjunction
with the Vitotwin 300-W
AAir vent valve
BDHW
CTemperature sensor B3
DHeating water flow, Vitotwin 300-W
EN/A
FHeating water flow, heating circuit
GTemperature sensor B4
HTemperature sensor B42
KHeating water return, heating circuit
LCold water
MHeating water return,
Vitotwin 300-W
NTemperature sensor B41
ON/A
PN/A
■To install temperature sensor B4 G,
fit the supplied connection elbow to
F.
■To install temperature sensor B41 N,
fit the supplied connection elbow to
M.
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

12
Electrical installation scheme
2
L
N
4
Vitotwin
230 V/50 Hz
L 1
N
PE
PE
L
N
N
PE
L
L 2
X100
3
2
F
X200
X301 k
2
x
2
3
4
X300 h
2
3
H5
2
n
2
3
b
2
b
2
1
3
2
1
3
2
X207
DM
3 A
VC 100
71
S
2
3
3 B
FBE
70
S
BSB
B3
B4
B41
WIRELESS
1
2
1
2
1
2
1
2
1
2
B42
B10
ATS
1
2
X1
ATS 4
6
PTSO B4
PTSU B41 7
STS B3 5
PTSU B10/42 8
Control unit 2
18
6
2 B Junction box
Low voltage
X301
X207
X300
6
6
6
QX1
PE
L 1
N
QX2
4
3
2
Z
L 2
QX4
4
3
2
M
4
3
2
J
EX2
EX1
B4
ATS
B41
B3
B42
B10
BSB
WIRELESS
X1 Junction box
Low voltage 2 B
X301
X207 X300
18
6
6
6
L 1
N
PE
L 2
QX3
61
41 51
Preparing for installation
Preparing for installation (cont.)
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13
VTS M1 42
M1 43
BSB
230 V/50 Hz
40
1 2
on
off
20
2
41 HK M1
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
VTS M3 62
M3 63
BSB
230 V/50 Hz
40
1 2
on
off
20
2
61 HK M3
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
M3 63
VTS M2 52
M2 53
BSB
230 V/50 Hz
40
1 2
on
off
20
2
51 HK M2
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
BSB 2 B
M
1~
M
1~
M
1~
M
1~
Required codes
Group Code Function
"System scheme" "5700:1" System scheme 1 as standard
function
"HC1" "5710:On" Heating circuit 1 installed
"HC2" "5715:On" Heating circuit 2 installed
"HC3" "5721:On" Heating circuit 3 installed
"Sensor input BX6" "5935:Buffer sensor
B42"
Buffer cylinder sensor B42 fitted
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

14
System version 2, ID: 4605452_1201_02
System with heating water buffer cylinder and DHW cylinder
Hydraulic installation scheme
--2B/ATS--
kW
21
8
20
--2B/B3--
--2B/B41--
--2B/B4--
5
6
1
4
--2B/WIRELESS--
3 A
--2/QX3--
9
30
3 B
7
--2B/B42--
--230V--
--52-- --20-- --2--
41
40
42
44
--41/2--
--41/52--
--41/20--
43
--BSB--
2 B
--B41--
--B4--
--B3--
--ATS--
-Wireless-
--B42--
--BSB--
--X1--
2
--230V--
--X300--
--X301--
--X207--
--QX3--
Preparing for installation
Preparing for installation (cont.)
5618 294 GB

15
Equipment required
Pos. Designation
1Vitotwin 300 W
with
2Weather-compensated control unit
2BJunction box for sensors and accessories (low voltage)
3ARemote control unit FBE
3BWireless base station FB
4Outside temperature sensor ATS
5Cylinder temperature sensor STS B3
6Buffer temperature sensor PTSO B4, top
7Sensor for power demand function B41
8Buffer temperature sensor PTSU B42, bottom
9Sub-mounting kit with 3/2-way valve
DHW heating
wP Vitocell mono mode DHW cylinder
wQ DHW circulation pump CP (electrical connection on site)
Heating water buffer
eP Heating water buffer cylinder Vitocell 100-E
rP Heating circuit 1 with mixer
rQ Extension kit for one heating circuit with mixer with integral mixer motor
and
rW Flow temperature sensor heating circuit M1
rE Heating circuit pump, heating circuit M1
rR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
tP Heating circuit 2 with mixer
tQ Extension kit for one heating circuit with mixer with integral mixer motor
and
tW Flow temperature sensor, heating circuit M2
tE Heating circuit pump, heating circuit M2
tR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
zP Heating circuit 3 with mixer (and plate heat exchanger for system sep-
aration)
zQ Extension kit for one heating circuit with mixer with integral mixer motor
and
zW Flow temperature sensor, heating circuit M3
zE Heating circuit pump, heating circuit M3
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

16
Pos. Designation
zR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
zZ Plate heat exchanger for system separation
Accessories (optional)
uP Vitocom 100, type GSM
uQ Central fault message
no pos.
no.
Wireless repeater for wireless remote control
no pos.
no.
230 V∼ extension
Installation of the Vitotwin 300-W with
the supplied sub-mounting kit:
Sub-mounting kit installation
instructions
Preparing for installation
Preparing for installation (cont.)
5618 294 GB

17
Electrical installation scheme
2
L
N
4
Vitotwin
230 V/50 Hz
L 1
N
PE
PE
L
N
N
PE
L
L 2
X100
3
2
F
X200
X301 k
2
x
2
3
4
X300 h
2
3
H5
2
n
2
3
b
2
b
2
1
3
2
1
3
2
X207
DM
3 A
VC 100
71
S
2
3
3 B
FBE
70
S
BSB
B3
B4
B41
WIRELESS
1
2
1
2
1
2
1
2
1
2
B42
B10
ATS
1
2
X1
ATS 4
6
PTSO B4
PTSU B41 7
STS B3 5
PTSU B10/42 8
Control unit 2
18
6
2 B Junction box
Low voltage
X301
X207
X300
6
6
6
QX1
PE
L 1
N
QX2
4
3
2
Z
L 2
QX4
4
3
2
M
4
3
2
J
EX2
EX1
B4
ATS
B41
B3
B42
B10
BSB
WIRELESS
X1 Junction box
Low voltage 2 B
X301
X207 X300
18
6
6
6
L 1
N
PE
L 2
QX3
61
41 51
9
UV
M
1~
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

18
VTS M1 42
M1 43
BSB
230 V/50 Hz
40
1 2
on
off
20
2
41 HK M1
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
VTS M3 62
M3 63
BSB
230 V/50 Hz
40
1 2
on
off
20
2
61 HK M3
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
M3 63
VTS M2 52
M2 53
BSB
230 V/50 Hz
40
1 2
on
off
20
2
51 HK M2
17
L
N
N
L
1
2
1
2
1
2
230 V/50 HzLow voltage
BSB 2 B
M
1~
M
1~
M
1~
M
1~
Required codes
Group Code Function
"System scheme" "5700:2" System scheme 2 as standard
function
"HC1" "5710:On" Heating circuit 1 installed
"HC2" "5715:On" Heating circuit 2 installed
"HC3" "5721:On" Heating circuit 3 installed
"Sensor input BX6" "5935:Buffer sensor
B42"
Buffer cylinder sensor B42 fitted
Preparing for installation
Preparing for installation (cont.)
5618 294 GB

19
System version 3, ID: 4605498_1201_01
System with floorstanding oil/gas boiler, heating water buffer cylinder and
DHW cylinder
Hydraulic installation scheme
--2B/ATS--
7
--2B/B41--
--2B/B4--
6
1
4
30
--2B/FUNK--
3A
3B
KW
21
20
--2B/B3--
5
--2A/QX2--
10
--11/21--
--2B/B10--
16
8
--230V--
--52-- --20-- --2--
41
40
42
44
--41/2--
--41/52--
--41/20--
43.
--BSB--
2B
--B41--
--B4--
--B3--
--ATS--
--Funk--
--B10--
--BSB--
--X1--
2
--230V--
--X300--
--X301--
--X207--
--11/5--
13
11
--230V--
--21--
--5-- --KM-BUS--
--96-- --3--
2A
--230V-- --X5--
--11/1--
12
--X10--
--QX2--
--X10--
--1--
17
--DE1--
--40--
18
--17/DE1-- --2A/X5--
15
9
--QX3--
--2/QX3--
Preparing for installation
Preparing for installation (cont.)
5618 294 GB
Installation

20
Equipment required
Pos. Designation
1Vitotwin 300 W
with
2Weather-compensated control unit
2A230 V∼ extension
2BJunction box for sensors and accessories (low voltage)
3ARemote control unit FBE
3BWireless base station FB
4Outside temperature sensor ATS
5Cylinder temperature sensor STS B3
6Buffer temperature sensor PTSO B4, top
7Buffer temperature sensor PTSU B41, bottom
8Flow temperature sensor, common flow (common flow sensor B10)
9Sub-mounting kit with 3/2-way valve
Heat source 2
qP Floorstanding oil/gas boiler
qQ Vitotronic 200, type KO1B and KO2B
qW Outside temperature sensor ATS
qE Cylinder temperature sensor STS
qR Boiler water temperature sensor KTS
qT Cylinder primary pump UPSB
qZ 3-way diverter valve
qU External extension EA1
qI Contactor relay
DHW heating
wP Vitocell dual mode DHW cylinder
wQ DHW circulation pump CP (electrical connection on site)
Heating water buffer
eP Heating water buffer cylinder Vitocell 100-E
rP Heating circuit 1 with mixer
rQ Extension kit for one heating circuit with mixer with integral mixer motor
and
rW Flow temperature sensor heating circuit M1
rE Heating circuit pump, heating circuit M1
rR 3-way mixer
or
Divicon (with 3-way mixer and heating circuit pump)
tP Heating circuit 2 with mixer
tQ Extension kit for one heating circuit with mixer with integral mixer motor
and
Preparing for installation
Preparing for installation (cont.)
5618 294 GB