Viessmann Vitodens 300 Istruzioni operative

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

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.)

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

5692 550 GB

For further instructions on individual steps, see pages indicated

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•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

Initial start-up, inspection, maintenance

5692 550 GB

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•• 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.)

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

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.)

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.)

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

(43.2to58.0MJ/m

LPG P version:

The boiler can be operated in the

Wobbe index range 21.4 to

22.5 kWh/m

(76.9to81.0MJ/m

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

(36.0to47.2MJ/

&LPG P to natural gas E

The boiler can be operated in the

Wobbe index range 12.0 to

16.1 kWh/m

(43.2to58.0MJ/

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.)

Initial start-up, inspection, maintenance

5692 550 GB

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