Viessmann C3HA Installation And Service Instructions For Contractors Download Page 19

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System version 3, ID: 4605498_1201_01

System with floorstanding oil/gas boiler, heating water buffer cylinder and
DHW cylinder

Hydraulic installation scheme

--2B/A

TS--

--2B/B41--

--2B/B4--

--2B/FUNK--

--2B/B3--

--2A/QX2--

--1

1/21--

--2B/B10--

--230V

--52--

--20--

--2--

--41/2--

--41/52--

--41/20--

43.

--BSB--

--B41-- --B4-- --B3-- --A

TS--

--Funk--

--B10--

--BSB--

--X1--

--230V

--X300-- --X301-- --X207--

--11/5--

--230V

--21--

--5--

--KM-BUS--

--96--

--3--

--230V

--X5--

--1

1/1--

--X10--

--QX2--

--X10--

--1--

--DE1--

--40--

--17/DE1--

--2A/X5--

--QX3--

--2/QX3--

Preparing for installation

Preparing for installation

(cont.)

5618 294 GB

Installation

Summary of Contents for C3HA

Page 1: ...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 ...

Page 2: ...f 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 Norther...

Page 3: ...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 bee...

Page 4: ...7 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 operati...

Page 5: ... 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 ...

Page 6: ...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 horiz...

Page 7: ...n 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 ...

Page 8: ...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 5618 294 GB ...

Page 9: ...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 D...

Page 10: ...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 ...

Page 11: ...Heating water flow heating circuit G Temperature sensor B4 H Temperature sensor B42 K Heating water return heating circuit L Cold water M Heating water return Vitotwin 300 W N Temperature sensor B41 O N A P N 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...

Page 12: ... 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...

Page 13: ... on off 20 2 51 HK M2 17 L N N L 1 2 1 2 1 2 230 V 50 Hz Low 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 instal...

Page 14: ... 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 ...

Page 15: ...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 t...

Page 16: ...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 ...

Page 17: ...SS 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 c...

Page 18: ...40 1 2 on off 20 2 51 HK M2 17 L N N L 1 2 1 2 1 2 230 V 50 Hz Low 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 ...

Page 19: ...41 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 ...

Page 20: ... 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...

Page 21: ...er 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 requires extension EA1 uW External set value 0 to 10 V requires extension EA1 uE External hook up Requires extension EA1 External blocking External demand External operating program changeover uR Radio clock receiver no pos no W...

Page 22: ...71 S 3 4 DE3 40 11 96 20 21 UPSB 15 M 1 28 145 1 KTS 14 3 EA1 191 9 15 41 7 73 DE2 DE1 1 17 41 150 X12 41 X12 2 41 7 50 1 2 3 1 2 1 2 1 2 1 2 3 4 1 145 2 18 K1 A1 A2 22 21 X5 1 2 A X5 2 2 A KO1B KO2B EA1 ATS 12 74 1 2 3 L N L N L N S P Ö 1 2 L N L N 1 2 1 2 Preparing for installation Preparing for installation cont 5618 294 GB ...

Page 23: ...2 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 Hz Low 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 Hz Low voltage BSB 2 B M 1 M 1 M 1 M 1 Preparing for installation Preparing for installation cont 5618 294 GB Installation ...

Page 24: ...E 1 2 1 2 1 2 1 2 1 2 1 2 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 61 41 51 2 B 3 2 1 1 2 3 4 1 2 1 2 3 1 2 3 1 2 3 1 2 BSB B3 B4 B41 WIRELESS B42 B10 ATS Control unit 2 7 QX1 QX4 QX2 2 1 1 PE L N L 2 PE L 1 N EX2 EX1 QX1 QX4 QX2 EX2 EX1 40 X5 X4 X3 X10 X1 16 UV EA1 K1 230 V 50 Hz 1 2 3 4 1 2 3 4 L 2 PE L 1 N L 2 PE L 1...

Page 25: ...nstalled Relay output QX2 5891 Heat request K27 Heat request K27 diverter valve demand heat source 2 Relay output QX4 5894 Suppl source control K32 Additional heat source control K32 lift block on heat source 2 Sensor input BX6 5935 Common flow sensor B10 Common flow sensor B10 fitted common flow temperature sen sor Vitotronic 200 coding addresses General 3A 3 External blocking General 61 1 Cylind...

Page 26: ...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 16 15 14 17 13 18 10 30 R1 230V S2 S1 31 31 S1 31 S2 31 R1 11 X3 5 6 34 32 33 230V X3 5 6 X4 3 4 X4 1 2 11 2 A 230V X5 X10 EX2 Equipment required Pos Designation 1 Vitotwin 300 W with 2 Weather compensated control unit Preparing for installation Preparing for installatio...

Page 27: ...xpansion vessel DHW heating wP Vitocell mono mode DHW cylinder wQ DHW circulation pump CP electrical connection on site Heating water buffer eP Heating water buffer cylinders eQ Vitosolic for buffer changeover eW 3 way diverter valve R1 on Vitosolic eE Temperature sensor S1 on Vitosolic collector temperature sensor eR Temperature sensor S2 on Vitosolic collector temperature sensor rP Heating circu...

Page 28: ...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 requires extension EA1 uW External set value 0 to 10 V requires extension EA1 uE External hook up requires extension EA1 External blocking External demand External operating program changeover no pos no Radio clock receiver n...

Page 29: ...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 2 A 230 V extension 31 3 2 1 1 2 3 4 1 2 1 2 3 1 2 3 1 2 3 1 2 Control unit 2 7 QX1 QX4 QX2 2 1 1 PE L N L 2 PE L 1 N EX2 EX1 QX1 QX4 QX2 EX2 EX1 40 X5 X4 X3 X10 SD1 R1L 230 V 50 Hz 1 2 3 4 1 2 3 4 L 2 PE L 1 N L 2 PE L...

Page 30: ...TS 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 Hz Low 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 Hz Low voltage BSB 2 B M 1 M 1 M 1 M 1 Preparing for installation Preparing for installation cont 5618 294 GB ...

Page 31: ...13 PROG PROG1 12 11 4 3 2 1 S1 S2 L N 20 SOL 17 16 13 R2 N 14 R1 N 18 230 V 50 Hz 15 KOL 21 19 31 145 33 34 32 SD1 10 9 PWM 6 5 S3 230 V 50 Hz Low voltage KKR FSK UV R1 230 V 50 Hz Low voltage 2 A X5 EX2 M 1 M 1 Preparing for installation Preparing for installation cont 5618 294 GB Installation ...

Page 32: ... heating Sensor input BX6 5935 Buffer sensor B42 Buffer cylinder sensor B42 fitted Function input EX2 5982 Auxiliary burner block Block on auxiliary burner during changeover to solid fuel mode Preparations for boiler installation Danger The product contains ceramic fibres If handled incorrectly fibre dust may be released Observe the stipulations of the Technical Guidelines for the Han dling of Haz...

Page 33: ...33 Dimensions 900 Ø 60 Ø 100 480 230 480 Preparing for installation Preparing for installation cont 5618 294 GB Installation ...

Page 34: ...re gas connection to TRGI or local regulations 3 Prepare electrical connections Information on the power supply The power supply for the Vitotwin 300 W must have sepa rate MCB fuse protection Connect the power supply directly from the distribution board as per connection conditions of your power supply utility and VDE 0100 IEE or local wiring regulations not from a final consumer circuit Never con...

Page 35: ... building s main meter should have a resist ance which is as low as possible Therefore observe the cable length and cross section Recommended cable cross sec tion 3 x 2 5 mm2 Preparing for installation Preparing for installation cont 5618 294 GB Installation ...

Page 36: ... so that it is exactly horizontal As option a self supporting mounting frame can be used for installation Depending on the nature of the installa tion room e g sound reflecting tiled walls or lightweight partition walls a self supporting mounting frame accessory is available for use Provide additional sound insulation measures on site if nec essary to minimise structure borne noise Installation wi...

Page 37: ...id Installation aid installation instructions Installation with self supporting mounting frame Self supporting mounting frame installation instructions Installation sequence Fitting the wall mounting bracket cont 5618 294 GB Installation ...

Page 38: ...egment and suspend from the wall mounting bracket 2 Remove lower packing segment 3 Align the Vitotwin 300 W vertically and horizontally in all three axes Note Take any additional measures required on site Installation sequence Mounting the boiler 5618 294 GB ...

Page 39: ...39 2 2x 1 Installation sequence Removing the front panel 5618 294 GB Installation ...

Page 40: ... the Stirling engine plate and check levels The circular level is packed sepa rately with the gas restrictors The inclination along all axes must be 1 bubble no more than halfway out of the marked area 3 If necessary alter the position by adjusting the rubber dampers on the rear boiler panel and the wall mount ing bracket Installation sequence Removing the front panel cont 5618 294 GB ...

Page 41: ...41 Pivoting the control unit forwards 2 1 2x Installation sequence Removing the front panel cont 5618 294 GB Installation ...

Page 42: ...42 1 2 Installation sequence Removing the transport brackets 5618 294 GB ...

Page 43: ...e During commissioning flue gas may escape from the condensate drain Fill the siphon with water before commissioning 2 1 1 Take the siphon out of the retainer and remove inlet pipe If necessary remove the drain pipe and power cable 2 Pour water into the inlet connection Installation sequence Removing the transport brackets cont 5618 294 GB Installation ...

Page 44: ... Flue system installation instruc tions Condensate connection B A Connect condensate drain A and safety valve drain B with a constant fall and connect the pipe vent to the public sewer Installation sequence Flue outlet 5618 294 GB ...

Page 45: ... Note For the tightness test use only suita ble and approved leak detecting agents EN 14291 and devices Leak detection agents with unsuita ble constituents e g nitrites sul phides can cause material damage Remove residues of the leak detec tion agent after testing Installation sequence Gas connection 5618 294 GB Installation ...

Page 46: ...er and the gas valve Max test pressure 150 mbar Where higher pressure is required for tightness tests disconnect the boiler and the gas valves from the gas sup ply pipe undo the fitting 3 Vent the gas line Installation sequence Gas connection cont 5618 294 GB ...

Page 47: ... 2 1 2x 3 Terminal connections Note See the connection and wiring diagram on page 161 for an overview and layout of terminals Installation sequence Opening the control unit casing 5618 294 GB Installation ...

Page 48: ...ccessories The sensors and accessories are con nected to the supplied junction box Attach the junction box to the wall in an appropriate position Cable length approx 1 0 m Installation sequence Terminal connections cont 5618 294 GB ...

Page 49: ...x Installation North or north westerly wall 2 to 2 5 m above ground level in multi storey buildings in the upper half of the second floor Not above windows doors or vents Not immediately below balconies or gutters Never render over Installation sequence Terminal connections cont 5618 294 GB Installation ...

Page 50: ...B B41 B4 ATS B42 B10 B A Cylinder temperature sensor B 3 B Buffer temperature sensor B 42 C Buffer temperature sensor B 41 D Buffer temperature sensor B 4 E Junction box See the applicable system scheme from page 8 onwards for use and layout of the sensors Installation sequence Terminal connections cont 5618 294 GB ...

Page 51: ... Funk 2 1 2 1 2 3 4 1 2 3 4 b B B3 BSB B41 B4 ATS B42 B10 A Common flow sensor common flow temperature sensor B Junction box See system version 3 on page 19 for use and layout of the common flow sensor Installation sequence Terminal connections cont 5618 294 GB Installation ...

Page 52: ... 3 2 F 4 3 2 Z L N PE L L N PE X200 A B EX2 EX1 QX3 QX4 QX2 A 3 way diverter valve B Plug on plug in strip X200 in the control unit Connection to the control unit See separate installation instruc tions Installation sequence Terminal connections cont 5618 294 GB ...

Page 53: ... 2 BSB BSB B4 B41 C 2 B A Extension kit for heating circuit with mixer B Junction box C Heating circuit 2 and 3 with mixer Note Never interchange wires See separate installation instruc tions Installation sequence Terminal connections cont 5618 294 GB Installation ...

Page 54: ...itter for remote control 1 2 3 4 ATS A B3 1 2 Funk B C B42 B10 A Wireless transmitter B Connecting cable C Junction box See separate installation instruc tions Installation sequence Terminal connections cont 5618 294 GB ...

Page 55: ...ncorrect core allocation can result in serious injury and dam age to the appliance Take care not to interchange wires L1 and N An isolator must be installed in the power cable to simultaneously isolate all non earthed conductors from the mains with at least 3 mm contact sep aration The integral circuit breaker ful fils this function Max fuse rating 16 A Installation sequence Terminal connections c...

Page 56: ...56 1 Guide the power cable through the opening in the bottom panel and insert a diaphragm grommet in the opening Installation sequence Terminal connections cont 5618 294 GB ...

Page 57: ...switch in the control unit B Internal circulation pump C AC meter 2 Connect the power cable to an appli ance junction box on site Note Replace the main power meter with a bi directional power meter Installation sequence Terminal connections cont 5618 294 GB Installation ...

Page 58: ...am aged if they touch hot compo nents When routing and securing con necting cables on site ensure that the maximum permissible temperatures for these cables are not exceeded Mounting the front panel 2x 1 2 Installation sequence Terminal connections cont 5618 294 GB ...

Page 59: ...rner 65 10 Entering a fixed day 65 11 Checking the gas type 65 12 Converting the gas type 66 13 Measuring the static pressure and supply pressure 68 14 Checking the balanced flue system for tightness annular gap check 69 15 Auxiliary burner removal 70 16 Checking the burner gasket and burner gauze assembly 71 17 Checking the ignition and ionisation electrode for auxiliary burner 73 18 Checking the...

Page 60: ... of safety valves 25 Checking the flue system for unrestricted flow and tightness 26 Checking for firm terminal connections 78 27 Checking all gas equipment for tightness at operating pressure 79 28 Flue gas emissions test 79 29 Matching the control unit to the heating system 81 30 Adjusting the heating curve 81 31 Adjusting screed drying 83 32 Instructing the system user 84 Commissioning inspecti...

Page 61: ...down When working on components containing water ensure that moisture does not enter the control unit or the power supply unit Never damage or open the Stir ling engine or subject it to mechanical loads Maintenance work on the Stirling engine The Stirling engine is more or less main tenance free The Stirling generator is maintenance free Ceramic materials are used in the Stirling engine If work st...

Page 62: ...all water softening system for heating water see Viessmann Vitoset price list Antifreeze suitable for heating sys tems can be added to the fill water The antifreeze manufacturer must ver ify its suitability A C B 1 Checking the pre charge pressure of the diaphragm expansion vessel on site 2 Close the gas shut off valve 3 Open the shut off valves A and B on the heating water side 4 Fill the heating...

Page 63: ...63 Venting the boiler D Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB Service ...

Page 64: ...ose valves C and D open shut off valves A and B on the heating water side 5 Adjust system pressure at fill valve C to 1 0 bar Venting the heating system 1 Vent heating system by bleeding the radiators Vent the heating water buffer cylinder separately when operating with a multi mode heating water buffer cyl inder see page 8 2 Check the system pressure Commissioning inspection maintenance Further d...

Page 65: ... supply utility see page 115 Entering a fixed day Enter the day and month as the fixed day in parameter 9100 e g 01 01 See also page 104 The fixed day needs to be specified for documentation purposes in case an application for a tax rebate is submitted for the amount of gas used by the Stirling burner Checking the gas type The appliance is set up for operation with natural gas E The burners need t...

Page 66: ...pe Replace the gas restrictors on both burn ers The gas restrictors are packed sep arately and shipped with the boiler Gas restrictor assignment Gas type Burner Identification Drilled hole 7 mm Natural gas E Stirling 39 3 9 Auxiliary 37 3 7 Natural gas LL Stirling 44 4 4 Auxiliary 42 4 2 Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB ...

Page 67: ...tural gas LL into the Stirling burner see previous table 3 Insert gas pipes A and B with new gaskets E and tighten the union nuts 4 Check the CO2 or O2 content for both burners see page 79 Danger Escaping gas leads to a risk of explosion Check all fittings for gas tight ness Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB Service ...

Page 68: ... on gas appliances A 1 Close the gas shut off valve 2 Undo the screw inside test nipple A IN on the gas train but never remove and connect the pressure gauge 3 Open the gas shut off valve 4 Check the static pressure and record the value in the report on page 184 Set value max 25 mbar 5 Start the boiler Commissioning inspection maintenance Further details regarding the individual steps cont 5618 29...

Page 69: ...xplo sion Check for gas tightness Open the gas shut off valve start the boiler and check for tightness at test nipple A Supply pressure flow pressure Action less than 17 4 mbar Do not take the appliance into use and notify the gas supply utility 17 4 to 25 mbar Start the boiler Above 25 mbar Install a separate gas pressure governor upstream of the system and regulate the pre charge pressure to 20 ...

Page 70: ... be sufficient to check the CO2 or O2 concentration in the combustion air at the annular gap of the balanced flue pipe The flue pipe is deemed to be gas tight if the CO2 concentration in the combus tion air is no higher than 0 2 or the O2 concentration is at least 20 6 If actual CO2 values are higher or O2 val ues are lower then pressure test the flue pipe with a static pressure of 200 Pa Auxiliar...

Page 71: ...s the earth cable 5 Undo the union nut on gas air duct D 6 Undo four screws from the burner cover and remove burner E Please note If the wire gauze is damaged this can affect the burner func tion Never rest the burner on the gauze assembly Checking the burner gasket and burner gauze assembly Check burner gasket A and burner gauze assembly E for possible damage and replace if required Commissioning...

Page 72: ...ation ring D 3 Undo four Torx screws and remove burner gauze assembly E with gas ket F 4 Insert new burner gauze assembly E with new gasket F and secure Torque 3 5 Nm 5 Fit thermal insulation ring D 6 Fit electrodes B Torque 4 5 Nm Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB ...

Page 73: ...skets and adjust them as required Tighten the elec trode fixing screws with 4 5 Nm Checking the ignition and ionisation electrode of the Stirling burner Danger The Stirling engine contains com ponents made from ceramic fibres which are not released if handled correctly The use of incorrect procedures when removing the electrodes can lead to the release of ceramic fibres Observe the stipulations of...

Page 74: ...k the electrodes for wear and contamination 4 Clean the electrodes with a small brush not with a wire brush or sand paper 5 If the electrodes are damaged replace the electrodes with the gas ket Tighten the electrode fixing screws with 1 5 Nm Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB ...

Page 75: ...ever use brushes to clean the heating surface B A 01 Remove separating plate A from heating surface B 02 Close opening in the lower rear part of heating surface B seal with adhesive tape so that liquids can not enter the Stirling burner Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB Service ...

Page 76: ...all separating plate A and tighten screws with 1 5 Nm Note Ensure the separating plate is fitted correctly 08 Install the burner and tighten the screws diagonally with 8 5 Nm 09 Fit the gas air duct with a new gas ket Tighten the union nut with a tor que of 100 Nm 10 Check the gas connections for tight ness Danger Escaping gas leads to a risk of explosion Check all fittings for gas tightness 11 Co...

Page 77: ... Fill siphon A with water via the inlet port and reinstall Check the length of the Stirling engine damping springs Note The spring length only needs to be checked and adjusted when Stirling engine cooled plate Omega gasket or springs are replaced Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB Service ...

Page 78: ...ck the diaphragm expansion vessel pre charge pressure on site and top up if required Checking for firm terminal connections 1 Check all cables for correct seating 2 Check cables on the Stirling engine for breakages and abrasion points Replace damaged cables Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB ...

Page 79: ... content must be within the following ranges CO2 content O2 content Stirling burner min 8 0 9 2 4 5 6 7 Engine auxiliary burner max 8 5 9 7 3 6 5 8 If the actual CO2 or O2 values lie outside the respective range 1 check the tightness of the balanced flue system see page 69 2 check the static pressure and the sup ply pressure see page 68 Performing the test A 1 Connect a flue gas analyser at test p...

Page 80: ... Record the actual value on page 184 of the commissioning service report Setting the heating output 1 If necessary press ESC repeat edly until the default display is shown 2 Press Ð this activates the emis sions test function see page 160 3 Press OK Eng burner min flashes on the dis play 4 Select the individual output settings with rotary selector J Eng burner min Stirling burner minimum Eng Supp ...

Page 81: ...justable value flashes 9 Set the required value function with the rotary selector 10 Confirm the selected item with OK The value stops flashing and has therefore been accepted See page 107 for a list of all codes for configuration Adjusting the heating curve The heating curve illustrates the relation ship between the outside temperature and the boiler water or flow tempera ture To put it simply th...

Page 82: ...emperature in C 2 5 2 75 3 3 5 4 2 Heating curve settings 30 40 50 60 70 80 90 20 10 0 10 20 Outside temperature in C Flow temperature in C 1 5 3 A B 0 5 Adjust the heating curve separately for each heating circuit Commissioning inspection maintenance Further details regarding the individual steps cont 5618 294 GB ...

Page 83: ...uit is regulated automatically via the set parameters This function comes to an end when the set time expires or the setting is returned to Off Note The screed drying function is only appro priate for heating circuits with mixers Observe EN 1264 The report to be provided by the heating contractor must contain the following heat up details Heat up data with respective flow tem peratures Max flow te...

Page 84: ...w temperature C 1 5 10 15 Days 40 35 30 25 20 7 5 45 50 55 1 0 A B Flow temperature as per temperature profile Flow temperature C 25 Days 25 1 0 C Constant flow temperature Instructing the system user The system installer should hand the operating instructions to the system user and instruct the user in operating the system Commissioning inspection maintenance Further details regarding the individ...

Page 85: ... control level Parameters and functions for mainte nance and service which are not required as often can be accessed on the Engineer control level 4 Confirm the selected control level with OK 5 Turn rotary selector G until the required function range is indicated 6 Confirm the selected item with OK 7 Turn rotary selector G until the required menu item is indicated The relevant code no is shown in ...

Page 86: ...2 25 10 Operator section Function Code Operat ing level Setting options Delivered condition Language 20 E English German French Italian Dutch Spanish Portuguese Danish Slovakian Czech German Operator section info 22 F2 Temporarily Permanent ly Temporari ly Operation lock 26 F2 Off On Off Programming lock Remove lock 1 Hold down ESC and OK for 3 s simultane ously 2 Return codes 26 or 27 to Off 27 F...

Page 87: ...control unit and its effects on the heating circuits is assigned by the fol lowing coding addresses Coding addresses 40 42 47 and 54 are only displayed on the remote control unit Device address See separate remote con trol unit documents 40 F1 Room unit 1 Room unit 2 Room unit 3 P Operator unit 1 Operator unit 2 Operator unit 3 P Service unit Assignment device 1 42 F1 Heating cir cuit 1 Heating ci...

Page 88: ...Heating cir cuit 1 only All assigned heating cir cuits Heating cir cuit 1 only Readjustment room sensor 54 F2 3 to 3 C 0 0 Software version 70 F2 00 0 to 99 9 Wireless Function Code Operat ing level Setting options Delivered condition The following coding addresses are only displayed in conjunction with a remote control unit and only on the remote control unit Room unit 1 130 F1 Delete de vice Yes...

Page 89: ...de vice Yes No Delete all devices 140 F1 Delete all devi ces Yes No Time prog heating circuit 1 Function Code Operat ing level Setting options Delivered condition Preselection 500 E Mo Su Mo Fr Sa Su Every week day individu ally Mo Su 1st phase on 501 E 00 00 to 24 00 h 06 00 1st phase off 502 E 00 00 to 24 00 h 22 00 2nd phase on 503 E 00 00 to 24 00 h 2nd phase off 504 E 00 00 to 24 00 h 3rd pha...

Page 90: ...st phase on 521 E 00 00 to 24 00 h 06 00 1st phase off 522 E 00 00 to 24 00 h 22 00 2nd phase on 523 E 00 00 to 24 00 h 2nd phase off 524 E 00 00 to 24 00 h 3rd phase on 525 E 00 00 to 24 00 h 3rd phase off 526 E 00 00 to 24 00 h Standard values All time phases in the time program for heating circuit 2 are reset to their factory settings 536 E No Yes No Time prog heating circuit 3 Function Code Op...

Page 91: ...56 E No Yes No Time program 4 DHW Domestic hot water Function Code Operat ing level Setting options Delivered condition Preselection 560 E Mo Su Mo Fr Sa Su Every week day individu ally Mo Su 1st phase on 561 E 00 00 to 24 00 h 06 00 1st phase off 562 E 00 00 to 24 00 h 22 00 2nd phase on 563 E 00 00 to 24 00 h 2nd phase off 564 E 00 00 to 24 00 h 3rd phase on 565 E 00 00 to 24 00 h 3rd phase off ...

Page 92: ...e off 604 E 00 00 to 24 00 h 3rd phase on 605 E 00 00 to 24 00 h 3rd phase off 606 E 00 00 to 24 00 h Standard values All time phases in time pro gram 5 are reset to their factory settings 616 E No Yes No Holiday program heating circuit 1 Function Code Operat ing level Setting options Delivered condition Holiday period HC1 Start Day 1 642 E 01 01 to 31 12 Holiday period HC1 End Last day 643 E 01 0...

Page 93: ...HC3 End Last day 663 E 01 01 to 31 12 Holiday operating level HC3 668 E Frost protec tion Reduced Frost pro tection Heating circuit 1 Function Code Operat ing level Setting options Delivered condition Room temperature comfort setpoint 710 E 6 to 35 C 20 0 Room temperature re duced setpoint 712 E 6 to 35 C 14 0 Room temperature frost protection setpoint 714 E 4 to 35 C 4 0 Heating curve slope see p...

Page 94: ...w Radiator medium Room temp limitation 760 F2 0 5 to 4 0 C 2 0 Quick setback setback mode 780 F2 Off Down to re duced set point Down to frost prot setpoint Down to re duced set point Opt start max opt ener gy with optimum energy see page 153 789 F2 0 to 480 min 00 00 00 00 80 00 240 Start optimisation max advance see page 153 790 F2 0 to 360 min 00 00 00 00 06 00 0 Optimum stop control max advance...

Page 95: ...drying func tion see page 83 850 F2 Off Functional heating Curing heat ing Functional curing heat ing Curing functional heating Manually Off Floor curing setp man ually 851 F2 0 to 95 C 25 Flow temp setpoint screed drying 855 F2 0 to 95 C 0 Screed drying day 856 F2 0 to 32 days 0 Floor curing days com pleted 857 F2 0 to 32 days 0 Heating circuit 1 with buffer The heating circuit is con nected to a...

Page 96: ... Room temperature comfort setpoint 1010 E 6 to 35 C 20 0 Room temperature re duced setpoint 1012 E 6 to 35 C 14 0 Room temperature frost protection setpoint 1014 E 4 to 35 C 4 0 Heating curve slope see page 81 1020 F1 0 10 to 4 00 1 40 Heating curve displace ment see page 81 1021 F1 4 5 to 4 5 C 0 0 Summer winter heating limit see page 159 1030 F1 8 to 30 C 18 24 hour heating limit see page 159 10...

Page 97: ...t point Opt start max opt ener gy see page 153 1089 F2 0 to 480 min 00 00 00 00 80 00 240 Start optimisation max advance see page 153 1090 F2 0 to 360 min 00 00 00 00 06 00 0 Optimum stop control max advance see page 153 1091 F2 0 to 360 min 00 00 00 00 06 00 60 Start room temp re duced setpoint in crease 1100 F2 30 to 10 C 5 End room temp re duced setpoint in crease 1101 F2 30 to 10 C 14 Frost pr...

Page 98: ...2 0 to 95 C 0 Screed drying day 1156 F2 0 to 32 days 0 Floor curing days com pleted 1157 F2 0 to 32 days 0 Heating circuit 2 with buffer The heating circuit is con nected to a heating water buffer cylinder 1170 F2 No Yes Yes Heating circuit 2 with prim contr system pump Connecting line to the heating circuit with without upstream control equip ment or feed pump 1172 F2 No Yes Yes Optg mode change ...

Page 99: ...see page 81 1321 F1 4 5 to 4 5 C 0 0 Summer winter heating limit see page 159 1330 F1 8 to 30 C 18 24 hour heating limit see page 159 1332 F2 10 to 10 C 0 Flow temp setpoint min 1340 F2 8 to 95 C 20 Flow temp setpoint max 1341 F2 8 to 95 C 80 Room temperature in fluencing factor 1350 F2 0 to 100 0 Type room controller see page 160 1359 F2 Manually Radiator fast Radiator me dium Radiator slow Floor...

Page 100: ...x advance see page 153 1391 F2 0 to 360 min 00 00 00 00 06 00 60 Start room temp re duced setpoint in crease 1400 F2 30 to 10 C 5 End room temp re duced setpoint in crease 1401 F2 30 to 10 C 14 Frost prot plant HC pump 1410 F2 Off On On Mixer setpoint boost differential temperature 1430 F1 0 to 50 C 8 Actuator running time 1434 F2 30 to 873 s 120 Screed drying func tion see page 83 1450 F2 Off Fun...

Page 101: ...uit 3 with prim contr system pump Connecting line to the heating circuit with without upstream control equip ment or feed pump 1472 F2 No Yes Yes Optg mode change over 1500 F2 None Frost protec tion mode Reduced Comfort Automatic None DHW Function Code Operat ing level Setting options Delivered condition Nominal setpoint DHW 1610 E 8 to 68 C 60 DHW temperature re duced setpoint 1612 E 8 to 68 C 40...

Page 102: ...o 7 days 7 Day auxiliary function for DHW heating see page 158 1642 F2 Monday Tuesday Wednesday Thursday Friday Saturday Sunday Saturday Time for auxiliary func tion for DHW heating see page 158 1644 F2 00 00 to 23 50 Setpoint auxiliary func tion for DHW heating see page 158 1645 F2 55 to 95 C 68 Dwell time at setpoint auxiliary function for DHW heating see page 158 1646 F2 10 to 360 min 10 Auxili...

Page 103: ... C 70 Frost protection plant consumer circuit 1 pump 1860 F2 Off On On Excess heat draw con sumer circuit 1 1875 F 2 Off On On Consumer circuit 1 with buffer 1878 F2 No Yes Yes Consumer circuit 1 with prim contr system pump 1880 F2 No Yes Yes Consumer circuit 2 Function Code Operat ing level Setting options Delivered condition Flow temp setp cons re quest 2 1909 F2 8 to 120 C 70 Frost protection p...

Page 104: ...2 8 to 120 C 85 Frost prot plant boiler pump 2300 F2 Off On Off Energy meter Function Code Operat ing level Setting options Delivered condition Electric energy deliv ered 3111 E kWh Date fixed day value Function Code Operat ing level Setting options Delivered condition Fixed day see page 9100 F2 01 01 to 31 12 Burner control Function Code Operat ing level Setting options Delivered condition Maximu...

Page 105: ...harg ing see page 156 3213 F2 No restric tions Stirling burn er only First charg ing eng bu on ly Fir cha eng bu supp bu else No restric tions Supplementary source see page 155 Function Code Operat ing level Setting options Delivered condition Setpoint incr main source 3690 F2 0 to 10 C 10 Output limit main source 3691 F2 1 to 100 80 With DHW charging 3692 F2 Locked Substitute Comple ment Instantl...

Page 106: ... Buffer storage tank Function Code Operat ing level Setting options Delivered condition Full charging 4810 F2 Off Heating mode Always Off DHW storage tank Function Code Operat ing level Setting options Delivered condition DHW forward shift charging 5011 F2 00 30 to 04 00 h 01 00 Flow setpoint boost 5020 F2 0 to 30 C 15 Switching diff 5024 F2 0 to 20 C 2 Pump speed min 5101 F2 0 to 100 15 Pump spee...

Page 107: ...Heating circuit 1 5710 F1 Off On On Heating circuit 2 5715 F1 Off On Off Heating circuit 3 5721 F1 Off On Off Consumer circuit 1 5750 F2 Off Heating Off Consumer circuit 2 5751 F2 Off Heating Off Relay output QX1 5890 F2 None Alarm output K10 see page 55 Circulating pump Q4 Heat request K27 see page 155 DHW ctrl el em Q3 Suppl source control K32 see page 155 Alarm out put K10 Codes Changing codes ...

Page 108: ...Circulating pump Q4 Heat request K27 see page 155 DHW ctrl el em Q3 Suppl source control K32 see page 155 None Relay output QX3 5892 F2 None Alarm output K10 see page 55 Circulating pump Q4 Heat request K27 see page 155 DHW ctrl el em Q3 Suppl source control K32 see page 155 DHW ctrl el em Q3 Codes Changing codes cont 5618 294 GB ...

Page 109: ...Common flow sensor B10 Buffer sensor B42 Buffer sen sor B42 Function input EX1 power demand function see page 154 5980 F2 None Ext heat dem rel Eng Bu Auxiliary burner lock None Cont type input EX1 NC Contact closed must be opened to acti vate NO Contact open must be closed to activate 5981 F2 NC NO NO Function input EX2 power demand function see page 154 5982 F2 None Ext heat dem rel Eng Bu Auxil...

Page 110: ... of the sensor inputs is saved e g after remov ing a sensor This status is then not recorded as a fault when the sensors are checked on a daily basis at 0 00 h 6200 F2 No Yes No Save parameters If Yes is set the current parameter settings are saved as new default set tings The factory set tings are thus overrid den This does not include fields such as time and date programming unit wireless servic...

Page 111: ...ervice spe cial operation all time pro grams and metering func tions 6205 F2 No Yes No VVS Device ID 6218 F2 00 0 to 99 9 SW version subsys tem 6219 F2 00 0 to 99 9 Software version 6220 F2 00 0 to 99 9 Development index 6221 F2 0 to 99 Device hours run Note Hours run are already shown on delivery as each device undergoes a hot test before shipment 6222 F2 00 00 00 to 20833 00 00 h Cylinder forced...

Page 112: ...story 4 6806 E Fault date time History 5 6808 E Fault date time History 6 6810 E Fault date time History 7 6812 E Fault date time History 8 6814 E Fault date time History 9 6816 E Fault date time History 10 6818 E Fault date time Status operating states The following operating states can be scanned The state appears in plain text Function Code Operating lev el State heating circuit 1 8000 F2 State...

Page 113: ... controller state 8020 F2 State supplementary source 8022 F2 Relay test The following relay outputs can be switched subject to system equipment level The connected components thus become operational The mixers in the heating circuits are opened and closed via relay outputs QX21 and QX22 Function of the relay outputs if the Divicon heating circuit distributor and extension kit are in the delivered ...

Page 114: ...QX22 mixer extension 3 Relay output QX23 mixer extension 3 Input output test The displayed value shows a captured temperature or a switching state for example If is displayed either there is no component connected or the connection is faulty Operating level F2 Function Code From switching state To switching state Unit Outside temp B9 7730 50 0 50 0 C Boiler temp B2 7760 0 0 140 0 C Boiler temp B20...

Page 115: ...Frequency H3 7857 0 1000 Hz Contact state H4 7860 Open Closed Pulse counter H4 7861 0 65535 Frequency H4 7862 0 1000 Hz Signal input EX1 7911 0 230 V Signal input EX2 7912 0 230 V Service special operation service functions Function Code Operating level Setting options Maintenance interval A service message is generated after expiry of the period set here fault message 105 7044 F2 1 to 240 months ...

Page 116: ...e Function Code Operat ing lev el From switch ing state To switching state Unit Power 8200 E 0 2000 W Voltage 8201 E 0 300 V Current 8202 E 0 10 A Energy to date 8204 E 0 kWh Energy since reset 8205 E 0 kWh Engine frequency 8206 E 0 100 Hz Diagnostics heat generation Function Code Operat ing lev el From switch ing state To switching state Unit Boiler pump Q1 8304 F2 Off On Boiler pump speed 8308 F...

Page 117: ...ontr temp actual value set value 8354 F2 0 140 C Head temp actual val ue actual value set val ue 8360 F2 0 700 C Hours run boiler pump 8365 F2 0 65535 h Boiler throughput 8366 F2 0 1000 l min Boiler temp limiter 8370 F2 Open Closed Condensate switch 8372 F2 Open Closed State burner operation 8373 F2 Off 1 2 1 2 Boiler temp limitation 8374 F2 Inac tive Active Diagnostics consumers Function Code Ope...

Page 118: ...60 F2 Off On Room temperature heat ing circuit 2 actual value set value 8770 F2 0 0 50 0 C Flow temp heating cir cuit 2 actual value set value 8773 F2 0 0 140 0 C Room thermostat heat ing circuit 2 8779 F2 No de mand Demand State heating circuit pump 3 8790 F2 Off On State HC mixing valve 3 open 8791 F2 Off On State HC mixing valve 3 closed 8792 F2 Off On Room temperature heat ing circuit 3 actual...

Page 119: ...140 0 C Buffer temp actual val ue B3 8983 F2 0 0 140 0 C State relay output QX1 central fault message fa cility 9031 F2 Off On State relay output QX2 9032 F2 Off On State relay output QX3 diverter valve 9033 F2 Off On State relay output QX4 9034 F2 Off On State relay output QX21 mixer extension 1 9050 F2 Off On State relay output QX22 mixer extension 1 9051 F2 Off On State relay output QX23 mixer ...

Page 120: ...xer extension 3 9058 F2 Off On Other scans Information on energy generated and used and on runtimes and intervals for various components are displayed under coding addresses 9104 to 9284 This information is only partially relevant for system operation See the operating instructions for the Vitotwin 300 W for possible scans Service scans Diagnostics cont 5618 294 GB ...

Page 121: ...e fault message appears on the display along with a brief description For further information see page 123 2 Correct the fault A restart follows automatically Fault with display Îª 1 Press Å The fault message appears on the display along with a brief description For further information see page 123 2 Press Å again The type of reset is shown in the display 3 Correct the fault 4 Depending on the typ...

Page 122: ...over of the control unit 3 Hold down reset button A for at least 5 s Reset circuit breaker A B 1 Pivot control unit down and remove control unit cover A 2 Actuate B 3 Carry out service reset see above Troubleshooting Carry out service reset 5618 294 GB ...

Page 123: ...en sor see page 146 32 Flow sensor 2 Short circuit or lead break to flow temperature sensor heating circuit 2 40 Return sensor 1 Short circuit or lead break to return temperature sensor Check the return tempera ture sensor see page 143 50 DHW sensor 1 Short circuit or lead break to cylinder temperature sensor B3 Check the cylinder tempera ture sensor see page 140 60 Room sensor 1 Short circuit or ...

Page 124: ...eplace control unit PCB if necessary see page 138 NRP 92 Device electronics error 95 Time of day invalid Wrong time set Reset time 96 Minor SW error Software error Replace the control unit PCB see page 138 AR 97 SW or HW failure Fault on control unit PCB Carry out service reset Re place control unit PCB if nec essary see page 138 NRP 98 Exten sion module 1 Fault in extension module for heating cir...

Page 125: ...ent the heating system Check whether there is any throughput code 8366 in di agnostics heat generation Check function of 3 way diverter valve 157 Boiler flow thermo stat Temperature limiter in the safety chain has tripped Check the system pressure Vent the heating system Check whether there is any throughput code 8366 in di agnostics heat generation Check function of the circula tion pump Check fu...

Page 126: ...am biguous Stirling burner or auxiliary burner control unit have de tected a problem on start up Carry out a service reset and restart If the fault has not been rectified replace the control unit PCB see page 138 SR 254 Un known error code Fault without a defined fault code 257 Pack sensor Short circuit or lead break to internal appliance tempera ture sensor Check connections to plug X205 Check in...

Page 127: ...rry out a restart If the fault has not been rec tified replace the control unit PCB see page 138 AR 264 Supp bu BCU fail ure Internal communication fault in auxiliary burner 265 BCU failure Internal communication fault Carry out a service reset and restart If the fault has not been rectified replace the control unit PCB see page 138 SR 266 Fan fault Fan speed differs from set value Check fan power...

Page 128: ... Max flow temperature in crease exceeded AR 280 Inner iron over temp Generator base excess tem perature Thermostat has re sponded Check connecting cables be tween Stirling engine and control unit cables to plug X205 Check temperature at bottom of Stirling engine max 100 C Check whether there is a min flow rate of 240 l h code 8366 in diagnostics heat gen eration Notify Viessmann Technical Service ...

Page 129: ...2 Check plug in connection X205 connecting cables and plugs to circuit breaker Check cable harness If the fault recurs notify Viessmann Technical Serv ice SR 284 WCS overtemp The temperature of the Stir ling engine is too high Check balanced flue system Perform a visual check of seals between the boiler flue connection and the heat ex changer and between the heat exchanger and the ring burner Ensu...

Page 130: ...adjust if necessary see page 77 Check electrical output code 8200 in diagnostics engine If the output is 500 W notify Viessmann Technical Serv ice Check the temperature dif ferential at the Stirling head thermocouples in steady state condition code 7764 and 7764 in input output test If the differential 50 K reposition the ther mocouples remove yellow connection plug and plug in C to L or L to C Th...

Page 131: ... fault 284 and 281 Take steps to rectify fault 284 and 281 SR 291 WCS overt G83 Combined fault 284 and 282 Take steps to rectify fault 284 and 282 SR 292 WCS overt Alt Combined fault 284 and 283 Take steps to rectify fault 284 and 283 SR 293 WCS overt SC Combined fault 284 and 285 Take steps to rectify fault 284 and 285 SR 294 WCS eng head overt Combined fault 284 and 286 Take steps to rectify fau...

Page 132: ...eck balanced flue system Ensure that flue gases are not being recirculated If the fault has not been rec tified replace the control unit PCB see page 138 AR 299 False flame supp bu The auxiliary burner ionisa tion electrode has detected a faulty flame 300 Eng head undert SW Stirling head control temper ature too low Check thermocouple cables If the fault has not been rec tified replace the control...

Page 133: ... remove yellow connection plug and plug in C to L or L to C Then check electrical output code 8200 in diagnostics engine If the electrical output is too low replace the thermocouples If the fault recurs notify Viessmann Technical Serv ice AR 302 Eng head t cou ple diff Temperature differential be tween the Stirling head con trol and limit thermocouple is too high Check plug in connection X205 conn...

Page 134: ...ne stall Generator voltage 50 V if generator running AR 308 Stop resistor in tegrity Stop resistor test failed Check cables between the control unit and the resis tors Check that the cables are plugged in correctly See connection and wiring dia gram plug X100 on page 161 Check resistors replace if necessary see page 151 AR 309 Power fail detec tion Software fault mains failure detection Check elec...

Page 135: ... 21 no function Fault in extension kit heating circuit with mixer Insert sensor in slot Check extension kit and con necting cable 336 BX 22 no function Sensor in extension kit heat ing circuit with mixer inserted in the wrong position 337 B 1 no function Fault flow temperature sen sor heating circuit 1 Plug not inserted correctly Check connection see page 146 338 B 12 no function Fault flow temper...

Page 136: ...mocouples AR 5 s 397 Eng head t c cont rise AR 20 min 398 Eng head t c lim integ AR 5 s 399 Eng head t c lim rise AR 20 min 400 Flow dir heat gen Captured return temperature code 8314 higher than flow temperature code 8310 Check sensor leads Check control unit PCB and replace if necessary see page 138 421 Temp diff h ex eng bu Captured return temperature code 8314 higher than flow temperature code...

Page 137: ...ansformer Check balanced flue system Ensure that flue gases are not being recirculated UR 425 Rep loss of fl Supp bu Repeated auxiliary burner flame failure UR 428 Boiler flow eng bu Minimum flow rate to operate the Stirling burner not reached Check the system pressure Vent the heating system Check whether there is any throughput code 8366 in di agnostics heat generation Check function of the circ...

Page 138: ...in writing for claims purposes If subsidies have been applied for The subsidy provider is entitled to request proof of the amount of heat deliv ered for heating Therefore before replacing the control unit PCB calculate the amount of heat delivered for heating since the last fixed day Calculating the amount of heat delivered for heating Subtract the Heat delivered heating from fixed day 1 code 9105...

Page 139: ...10 kΩ 1 Pull plug 2K from the control unit 2 Test the resistance of the outside temperature sensor at the disconnec ted plug and compare it with the curve 3 Where actual values deviate severely from the curve values disconnect the wires at the sensor and repeat test on the sensor itself 4 Depending on the result replace the lead or the outside temperature sen sor Troubleshooting Repairs cont 5618 ...

Page 140: ... B41 B4 ATS B42 B10 B A Cylinder temperature sensor B3 B Buffer temperature sensor B42 or common flow sensor B10 common flow tem perature sensor C Buffer temperature sensor B41 D Buffer temperature sensor B4 E Junction box 1 Remove the plug to the respective sensor in the junction box Troubleshooting Repairs cont 5618 294 GB ...

Page 141: ...sistance in kΩ Sensor type NTC 10 kΩ 2 Test the resistance of the sensor at the disconnected plug and compare it with the curve 3 Replace the sensor in the case of severe deviation Checking boiler water temperature sensor A Troubleshooting Repairs cont 5618 294 GB Service ...

Page 142: ... 4 0 6 0 8 2 4 6 8 20 Resistance in kΩ Sensor type NTC 10 kΩ 2 Check the sensor resistance and compare it with the curve 3 Replace the sensor in the case of severe deviation Danger The sensor is immersed in the heating water risk of scald ing Drain the boiler before replac ing the sensor Troubleshooting Repairs cont 5618 294 GB ...

Page 143: ...143 Checking return temperature sensor B 1 Pull the leads from return tempera ture sensor B and check the resist ance Troubleshooting Repairs cont 5618 294 GB Service ...

Page 144: ...nsor type NTC 10 kΩ 2 Check the sensor resistance and compare it with the curve 3 Replace the sensor in the case of severe deviation Danger The sensor is immersed in the heating water risk of scald ing Drain the boiler before replac ing the sensor Troubleshooting Repairs cont 5618 294 GB ...

Page 145: ...145 Checking internal appliance temperature sensor A Troubleshooting Repairs cont 5618 294 GB Service ...

Page 146: ... 4 0 6 0 8 2 4 6 8 20 Resistance in kΩ Sensor type NTC 10 kΩ 2 Check the sensor resistance and compare it with the curve 3 Replace the sensor in the case of severe deviation Checking flow temperature sensor heating circuit BSB aJ 1 Remove plug from the extension for heating circuit with mixer Troubleshooting Repairs cont 5618 294 GB ...

Page 147: ... flow tem perature sensor at the disconnected plug and compare it with the curve 3 Where actual values deviate severely from the curve values disconnect the wires at the sensor and repeat test on the sensor itself 4 Depending on the result replace the lead or the flow temperature sensor Troubleshooting Repairs cont 5618 294 GB Service ...

Page 148: ...er water temperature is below approx 75 C check the following A 1 Pull the cables from thermal circuit breaker A 2 Check the continuity of the thermal circuit breaker with a multimeter 3 Remove the faulty thermal circuit breaker 4 Fit a new thermal circuit breaker and connect cables Troubleshooting Repairs cont 5618 294 GB ...

Page 149: ...hermocouples A 120 A B C 1 Fit transport brackets to the Stirling engine to prevent damage during replacement see page 42 2 Mark new thermocouple A 120 mm away from its tip Troubleshooting Repairs cont 5618 294 GB Service ...

Page 150: ...uple A undo locking screw B and remove thermocouple 4 Insert new thermocouple A right up to the mark on the sleeve tighten locking screw B and insert plug C 5 Remove the transport brackets again Troubleshooting Repairs cont 5618 294 GB ...

Page 151: ...151 Checking and replacing resistors B C A Troubleshooting Repairs cont 5618 294 GB Service ...

Page 152: ... 3 Replace resistors if necessary 4 Remove the r h side panel 5 Undo screws and remove faulty resistor B or C then fit new resis tor 6 Connect new resistor B or C to the plug 7 Insert resistor plug A into the control unit Check overtravel switch connection A A Check plug in connection and cable to overtravel switches A Troubleshooting Repairs cont 5618 294 GB ...

Page 153: ...n be adjusted in code 2212 and temperature limiter 100 C Burner sequence Initially the Stirling burner starts when a heat demand is issued If the set boiler water temperature is not reached or if the temperature drops further the auxiliary burner starts after a delay If the Stirling burner has developed a fault the auxili ary burner starts immediately 10 K 5 K TB 8 K 4 K A B C D E F B41 B42 B4 A T...

Page 154: ...temperature sensor B42 should be connected for the power demand function code 5935 in the deliv ered condition to Buffer sensor B42 The power demand function will only be activated if the heating water buffer cyl inder or DHW cylinder are still able to accept heat The Stirling burner is switched on once until buffer temperature sensor B41 rea ches the set temperature of 60 C or the time for forced...

Page 155: ...ture on the common flow temperature sensor common flow sensor B10 falls below the set flow temperature by the Switching diff on the diverter valve terminal QX2 switches and passes through the boiler The auxili ary heat source burner is enabled if the Switching integral code 3720 is reached When the auxiliary heat source is ena bled the set flow temperature for Vitotwin 300 W is increased by 10 K c...

Page 156: ...ing burner is enabled for DHW heating The auxiliary burner is only enabled in the event of a Stirling burner fault First charg eng bu only Only the Stirling burner is enabled for the first DHW heating operation of the day The auxiliary burner is only ena bled in the event of a Stirling burner fault Enable is unrestricted for any other DHW heating operations during the day Fir cha eng bu supp bu el...

Page 157: ... heating it is possible to choose between absolute mode and modulating mode delivered condition In modulating mode at the end of DHW heating the excess energy is used for central heating only relevant when using a multi mode heating water buffer cylinder The mode can be selected with code 1630 The following codes influence cylinder temperature control 1620 1630 1640 1641 1642 For a description see...

Page 158: ...heating starts again as soon as DHW heating is turned on again Note Whilst the auxiliary function for DHW heating is active there is a risk of scald ing in the vicinity of draw off points Frost protection If the temperature in the DHW cylinder falls to 5 C DHW is heated to 8 C Heating circuit control The set flow temperature of the heating circuits is determined by the following parameters Outside...

Page 159: ...tically switched off when the outside temperature exceeds the set value This function is subject to the adjusted outside temperature Daytime heating limit Coding addresses 732 1032 1332 Heating mode is switched on or off according to the outside temperature over the course of the day The heating circuit heating circuit pump is automatically switched off when the actual outside temperature exceeds ...

Page 160: ...ertia displayed by different heating systems and the building insulation Emissions test function The appliance can be switched to a spe cial mode by pressing the emissions test mode key ª appears on the display Set the output by using rotary selector J see page 80 The Stirling burner and the auxiliary burner are switched off They are only switched on again when the Stirling head temperature is 150...

Page 161: ...161 A B A1 Control PCB A Connection to junction box for sen sors and accessories junction box see page 163 B 3 way diverter valve Designs Connection and wiring scheme 5618 294 GB Service ...

Page 162: ...162 C D E F A2 Power supply unit C Vitocom 100 fault message D Power supply E Internal circulation pump F Net electricity meter Designs Connection and wiring scheme cont 5618 294 GB ...

Page 163: ...0 QX1 Floating contact QX1 QX2 Floating contact QX2 QX4 Floating contact QX4 EX1 Function input EX1 EX2 Function input EX2 QX1 Relay output QX1 QX2 Relay output QX2 QX4 Relay output QX4 fÖ Power supply Designs Connection and wiring scheme cont 5618 294 GB Service ...

Page 164: ...re sensor B42 or common flow sensor B10 common flow temperature sensor D Wireless transmitter E Extension kit for heating circuit with mixer F Extension kit 2 and 3 for heating cir cuit with mixer G Buffer temperature sensor B41 H Buffer temperature sensor B4 K Vitotwin 300 W control unit Designs Connection and wiring scheme cont 5618 294 GB ...

Page 165: ...ed Serial no see type plate A Assembly from this parts list Position number of the individual part within the assembly from this parts list Standard parts are available from your local supplier Parts lists Ordering parts 5618 294 GB Service ...

Page 166: ...166 B C E D G F A A Type plate B Sheet metal parts assembly Parts lists Overview of the assemblies 5618 294 GB ...

Page 167: ...t 0007 Profiled seal 0008 R h side section 0009 R h side section sound insulation mat 0010 Sound insulation mat 0011 L h side section 0012 L h side section sound insulation mat 0013 Top panel sound insulation mat 0014 Capacitor mounting bracket 0015 Hinged foot 0016 RW sound insulation mat 0017 Air distribution valve sound insu lation mat 0018 Sound insulation mat resistors T1 0020 Sound insulatio...

Page 168: ...07 0021 0021 0015 0015 0007 0007 0007 0006 0011 0012 0013 0010 0009 0002 0002 0004 0003 0006 0005 0003 0001 0004 0007 0005 0005 0012 0010 0009 0008 0017 0016 0014 0020 0018 0017 Parts lists Sheet metal parts assembly cont 5618 294 GB ...

Page 169: ... gas gasket 0006 Boiler flue connection 60 100 0007 Boiler flue connection plug 0008 Gasket DN 60 0009 Vitotwin condensate hose 0010 Siphon 0011 Level switch 0012 Hose 19 x 230 corrugated 0013 Diaphragm grommet DG36 14 0014 Siphon retainer 0015 Vitotwin pack Parts lists Heat cell assembly 5618 294 GB Service ...

Page 170: ...170 0007 0008 0015 0002 0004 0003 0012 0014 0013 0010 0011 0009 0001 0005 0007 0006 0008 Parts lists Heat cell assembly cont 5618 294 GB ...

Page 171: ...ng water return connection elbow 0010 Cheese head screw M4 x 12 5 pce 0011 Flue outlet gasket 0008 0009 0002 0003 0002 0010 0001 0005 0007 0006 0006 0006 0006 0004 0008 0010 0010 0010 0011 Burner assembly 0001 Thermal insulation ring 0002 Burner gasket 0003 Cylinder burner gauze assembly 0004 Burner gauze assembly gasket 0005 Gas air mixture connection flange 0006 Burner door flange gasket Parts l...

Page 172: ...al ring 27 x 38 x 3 0004 0013 0013 0005 0006 0013 0010 0008 0004 0002 0001 0001 0001 0012 0003 0004 0008 0010 0002 0001 0010 0008 0007 0009 0011 Air distribution valve assembly 0001 Slide housing with sleeves 0002 Double flow jet 0003 Double flow jet gasket 0004 Fan NRG 118 24 V 65 W 0005 Fan gasket 0006 Rotor with flow diverter Parts lists Burner assembly cont 5618 294 GB ...

Page 173: ...73 0007 Geared motor 24 V AC 0 22 W 0008 Grub screw M5 x 10 0003 0003 0005 0005 0008 0005 0008 0008 0003 0002 0004 0005 0006 0001 0007 Parts lists Air distribution valve assembly cont 5618 294 GB Service ...

Page 174: ... Ring burner connection flange 0009 Auxiliary burner gas pipe 0010 Stirling burner gas pipe 0011 Gas valve VGU86S 0012 Ignition transformer TQG42 0013 Gas line auxiliary burner 0014 Stirling burner gas supply line 0015 Gas connection manifold 0016 Connection hose 0017 Gas restrictor G20 auxiliary burner 0018 Gas restrictor G20 Stirling burner 0019 Screw 35 x 16 5 pce Parts lists Gas air route asse...

Page 175: ... 0018 0007 0007 0007 0007 0007 0007 0009 0007 0011 0012 0012 0007 0013 0010 0007 0011 0007 0014 0015 0007 0007 0004 0005 0007 0002 0004 0007 0006 0007 0008 0007 0007 0017 0007 0001 0002 0007 0007 0019 0019 Parts lists Gas air route assembly cont 5618 294 GB Service ...

Page 176: ...016 V clip Ø 110 closure M6 0017 Flue gas gasket 0018 Stirling thermal circuit breaker 0019 Thermocouples 0020 Hose clip DN 25 0021 Set of plug connector retainers 0022 Heating water return profile hose 0023 O ring 17 8 x 2 6 set 0024 Push fit elbow connector 90 0025 Temperature sensor retaining bracket 0026 Flue gas temperature sensor 0027 Ring burner insulation cover 0028 Ring burner internal in...

Page 177: ... 0002 0025 0019 0018 0004 0005 0005 0005 0005 0004 0001 0020 0020 0007 0023 0024 0021 0012 0005 0005 0011 0011 0004 0019 0023 0020 0020 0022 0004 0024 0021 0010 0014 0014 0026 0018 0015 0009 0030 0003 0030 0009 0002 0024 0023 Parts lists Stirling unit assembly cont 5618 294 GB Service ...

Page 178: ... 19 x 230 corrugated 0013 Diaphragm grommet DG36 14 0014 Heating water return connection pipe 0015 Temperature sensor 0016 Clip Ø 18 5 pce 0017 Safety valve 3 bar 0018 Connecting pipe 0019 Circulation pump motor UPM2 15 70 PWM 0020 Air vent valve 0021 Gasket 23 x 30 x 2 0022 Flow sensor connection pipe 0023 Flow sensor DN 15 0024 Union nut G 3 4 0025 Pump head VIUMP2 15 70 PWM 0026 O ring 17 8 x 2...

Page 179: ...0020 0025 0021 0026 0029 0007 0029 0010 0026 0027 0028 0004 0029 0011 0015 0002 0027 0026 0024 0018 0025 0019 0020 0021 0003 0003 0022 0021 0011 0016 0012 0013 0017 0011 0006 0009 0008 0003 0001 0030 Parts lists Hydraulic assembly cont 5618 294 GB Service ...

Page 180: ... air diverter cable harness 0028 Cable harness X2 X2 burner con trol unit 0029 Cable harness X205 X204 0030 Stirling burner ionisation cable 0031 Meter input power cable 0032 Single core non sheathed cable GN YE capacitor 0033 Generator cable harness 0034 Power supply unit cable harness SP110 24 V 0035 Power supply cable harness 0036 Overload switch cable set 0037 18 pole power cable with plug 003...

Page 181: ...181 Parts lists Control unit assembly cont 5618 294 GB Service ...

Page 182: ...ck white 0003 Special grease 0004 Installation and service instruc tions 0005 Wireless remote control unit installation instructions 0006 Operating instructions 0007 Transport bracket 0008 Gauge 0009 Circular level Parts lists Miscellaneous assembly 5618 294 GB ...

Page 183: ...183 Parts lists Miscellaneous assembly cont 5618 294 GB Service ...

Page 184: ...n content O2 for Engine burner min by vol for Engine Supp burner max by vol Carbon monoxide content CO for Engine burner min ppm for Engine Supp burner max ppm Generator output after 5 min operation Power Code 8200 in Diagnostics engine W Voltage Code 8201 in Diagnostics engine V Current Code 8202 in Diagnostics engine A Head temperature actual value Code 8360 in Diagnostics consum ers C Flow temp...

Page 185: ...Current Code 8202 in Diagnostics engine A Head temperature actual value Code 8360 in Diagnostics consum ers C Flow temp Code 8310 in Diagnostics consum ers C Return temp Code 8314 in Diagnostics consum ers C Heating contractor Address Electrical contractor Address Boiler commissioned Date Stirling generator commissioned Date Commissioning service reports Report cont 5618 294 GB Service ...

Page 186: ... C kW 3 5 to 26 Rated heating output range TV TR 75 60 C kW 3 2 to 24 6 Rated heat input range kW 3 6 to 25 2 Nominal electrical rating max kW 1 0 Total elect consumers max W 138 Connection values relative to the max load Natural gas E m3 h 2 61 Natural gas LL m3 h 3 11 Product ID _ 0085CM0150 Note The connection values are only for doc umentation purposes e g in the gas contract application or to...

Page 187: ...DE AR 4105 EN 60 335 2 102 EN 483 EN 61 000 3 2 EN 677 EN 61 000 3 3 EN 50 438 EN 62 233 In accordance with the following Directives this product is designated with _ 0085 92 42 EEC 2006 95 EC 2004 108 EC 2009 142 EC This product meets the requirements of the Efficiency Directive 92 42 EEC for con densing boilers Allendorf 1 January 2012 Viessmann Werke GmbH Co KG Authorised signatory Manfred Somm...

Page 188: ...oduct Vitotwin 300 W complies with the NOx limits specified by the 1st BImSchV Paragraph 6 Germany Allendorf 01 May 2011 Viessmann Werke GmbH Co KG Authorised signatory Manfred Sommer Certificates Manufacturer s certificate according to the 1st BImSchV Germany 5618 294 GB ...

Page 189: ...ration of conformity 187 DHW heating 156 Diagnostics 116 Diaphragm expansion vessel 62 78 Domestic hot water 91 E Electrical connections 34 Emissions test 79 Enabling the Stirling burner 65 External demand 92 F Fault codes 123 Fault message 55 123 Faults 121 Filling the heating system 62 Filling the system 62 Fill water 62 Fitting the burner 75 Fixed day 65 Flow temperature sensor 146 Flue gas emi...

Page 190: ...iphon 77 Small water softening system 62 Specification 186 Start Stop resistors 151 Start optimisation 154 Static pressure 68 Stirling springs 77 Stop optimisation 154 Supply pressure 68 Switching times 89 157 159 System pressure 62 System scheme 8 14 19 26 System schemes 81 System version 8 14 19 26 T Temperature limiter 148 Temperature sensors 140 Terminal connections 47 Test pressure 46 Thermoc...

Page 191: ...191 5618 294 GB ...

Page 192: ...type plate 7506537 Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5618 294 GB Subject to technical modifications ...

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