Viessmann C3TB Installation And Service Instructions For Contractors Download Page 188

Page: 188 / 188

188

Applicability

Serial No.:

7357351

Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: +44 1952 675000
Fax: +44 1952 675040
E-mail: [email protected]

Viessmann Werke GmbH & Co. KG
D-35107 Allendorf
Telephone: +49 6452 70-0
Fax: +49 6452 70-2780
www.viessmann.com

5775 636 GB

Subject to technical modifications.

Summary of Contents for C3TB

Page 1: ...or contractors VIESMANN Vitovalor 300 P Type C3TB 1 to 20 kW Micro CHP unit based on a fuel cell with integral gas condensing boiler Natural gas version For applicability see the last page VITOVALOR 300 P 5775 636 GB 1 2016 Please keep safe ...

Page 2: ...er Hot surfaces can cause burns Before maintenance and service work switch OFF the appliance and let it cool down Never touch hot surfaces on the boiler burner flue system or pipework Please note Electronic assemblies can be damaged by elec trostatic discharge Prior to commencing work touch earthed objects such as heating or water pipes to dis charge static loads Repair work Please note Repairing ...

Page 3: ...ocked flue systems or an inade quate supply of combustion air can cause life threatening poisoning from carbon monoxide in the flue gas Ensure the flue system is in good working order Vents for supplying combustion air must be non closable Extractors Operating appliances that extract air to the outside cooker hoods extractors air conditioning units etc can create negative pressure If the boiler is...

Page 4: ...sides 23 Mounting the diaphragm expansion vessel 24 Aligning the Vitovalor 300 P 25 Heating water and DHW connections 26 Balanced flue terminal 27 Routing drain lines 29 Gas connection 29 Opening the control unit enclosure on the gas condensing module 30 Electrical connections 31 Vitotronic 200 31 Process controller 32 Making the electrical connection between the fuel cell module and the gas conde...

Page 5: ...e system on the heating water and DHW sides 123 Checking the outside temperature sensor 126 Checking the boiler water temperature sensor cylinder temperature sensor or flow temperature sensor of low loss header 127 Checking the outlet temperature sensor 128 Checking the return temperature sensor 129 Checking the buffer temperature sensor 130 Checking the plate heat exchanger 130 Checking the flue ...

Page 6: ...gram 171 Fill program 171 Screed drying 171 Raising the reduced room temperature 173 Reducing the heat up time 174 Assigning heating circuits to the remote control 175 Electronic control unit on the peak load boiler 176 10 Connection and wiring dia gram Connection diagram internal gas condensing module 177 Connection diagram external gas condensing module 178 Differential temperature controller 17...

Page 7: ... point Do not dispose of component in domestic waste The steps in connection with commissioning inspec tion and maintenance are found in the Commission ing inspection and maintenance section and identified as follows Symbol Meaning Steps required during commissioning Not required during commissioning Steps required during inspection Not required during inspection Steps required during maintenance ...

Page 8: ... is installed close to the coast it should be positioned such that the flue gas and ventilation air apertures do not come into direct contact with saline air in order to prevent damage due to corrosion Minimum temperature inside the installation room 3 C Vitovalor 300 P in systems with photovoltaic and solar thermal equipment Operating the Vitovalor 300 P in conjunction with a photovoltaic or sola...

Page 9: ...ell module may be tilted up to 90 See following diagram Store the fuel cell module upright Please note To prevent damage to the appliance when transporting up or down stairs always keep the underside of the appliance lower than the top A Fig 2 A Appliance top Gas condensing module Please note Prevent damage to the appliance during han dling Never lay the gas condensing module on its front or side ...

Page 10: ...10 Dimensions of siting options 2250 1085 5 134 2147 2082 237 595 Fig 3 Fuel cell module to the left of the gas con densing module Preparing for installation Siting cont 5775 636 GB Installation ...

Page 11: ...tions on the gas and water sides Fitting accessories Before final siting attach all of the accessories that are to be mounted from the back of the boiler e g connec tion sets Please note Avoid damaging the appliance Connect all pipework free of load and torque stress Preparing connections on site Connection set installation instructions Preparing for installation Siting cont 5775 636 GB Installati...

Page 12: ...5 496 1085 5 480 377 516 237 595 898 456 104 83 B C Fig 6 B Fuel cell module to the right of the gas condensing module C Fuel cell module to the left of the gas condensing module Note All height dimensions have a tolerance of 15 mm on account of the adjustable feet Preparing for installation Preparing for installation cont 5775 636 GB Installation ...

Page 13: ... and EN 806 see page 26 Recommendation Install the safety valve above the DHW cylinder This protects the valve against soiling scaling and high temperatures 3 Prepare the connection from the fuel cell module and from the gas condensing module to on site drain or trap See diagram on page 12 4 Prepare gas connection to TRGI or local regula tions 5 Prepare electrical connections see following chap te...

Page 14: ...tallation and clarify any techni cal points as well as the acceptance procedure Hand the relevant application forms as per VDE AR N 4105 or local regulations to the relevant grid operator Application forms for German grid operators are available at www viessmann de Note Different documentation may be required by grid oper ators in other regions Metering generated power A net AC meter Z2 is integra...

Page 15: ...nal energy management not relevant for billing by the grid operator Arrangement of excess export when connected into a main LV distribution board RCD RCD kWh Z1 H AC 400 V 230 V K G F kWh Z2 1 E A C D B kWh Z3 N M Fig 9 A Vitovalor 300 P B Internal circulation pump C Internal consumers D GS protection E ON OFF switch F Meter cupboard G On site consumers H Property boundary K Low voltage grid M Inv...

Page 16: ...omer G Power distribution H On site consumers K Short circuit protection L Overload protection RCD M Vitovalor 300 P N GS protection O Inverter DC AC converter SEMAX 1 5 kVA P Fuel cell Z1 Balancing bi directional meter observe meter cir cuit Z2 Net electricity meter standard delivery Vitovalor 300 P Z3 Bi directional energy management not relevant for billing by the grid operator Preparing for in...

Page 17: ...ction L Overload protection RCD M Vitovalor 300 P N GS protection O Inverter DC AC converter SEMAX 1 5 kVA P Fuel cell U Power storage system inverter V Power storage unit Z1 Balancing bi directional meter observe meter cir cuit Z2 Net electricity meter standard delivery Vitovalor 300 P Z3 Bi directional energy management not relevant for billing by the grid operator Z4 Power storage management bi...

Page 18: ... P N GS protection O Inverter DC AC converter SEMAX 1 5 kVA P Fuel cell R GS protection for PV system S PV inverter T Photovoltaic system Z1 Balancing bi directional meter observe meter cir cuit Electricity meter for power export and drawing Z2a Export generation meter PV system power gen eration Z2b Export generation meter for power generation by Vitovalor 300 P standard delivery with Vitovalor 3...

Page 19: ... E Grid operator F Customer G Power distribution H On site consumers K Short circuit protection L Overload protection RCD M Vitovalor 300 P N GS protection O Inverter DC AC converter SEMAX 1 5 kVA P Fuel cell R GS protection for PV system S PV inverter T Photovoltaic system U Power storage system inverter V Power storage unit Z1 Balancing bi directional meter observe meter cir cuit Electricity met...

Page 20: ...n or meter cupboard or to the nearest suitable sub distribution board The Vitovalor 300 P is protected by a mains isolator Depending on the nature of the domestic grid or as required by DIN VDE 0100 410 a residual current device RCD may also be required Please note Switching off by means of an emergency stop switch for the heating system can damage the appliance Remove any emergency stop switches ...

Page 21: ...rectional energy management not relevant for billing by the grid operator Ensure adequate selectivity if any new RCD is instal led downstream of any existing circuit breaker In order to ensure complete selectivity of two residual current devices connected in series the fault current of upstream RCD A must be at least 3 times as high as that of RCD F used to protect the Vitovalor 300 P Adjust the a...

Page 22: ...22 Removing the front panel of the gas condensing module 1 3 5 4 2x 2 Fig 16 Installation sequence Installing the Vitovalor 300 P 5775 636 GB Installation ...

Page 23: ...ule connector G C Heating water return buffer cylinder Union nut G D Condensate drain hose gas condensing module E Heating water flow fuel cell module union nut G F Gas connection fuel cell module connector G G Heating water return fuel cell module connector G H Cables and leads K Condensate drain hose fuel cell module Installation sequence Installing the Vitovalor 300 P cont 5775 636 GB Installat...

Page 24: ...n the gas condensing module against the wall see page 25 06 Affix the spacers onto the side panel of the fuel cell module as shown 07 Attach the separate diaphragm expansion vessel standard delivery See page 24 08 Connect the gas and heating water lines to the fuel cell module using gaskets Torque G 30 Nm Torque G 10 Nm Route the lines in such a way that they do not kink Using cable ties attach th...

Page 25: ...the bracket supplied 6 Adjust the charge pressure in the diaphragm expansion vessel to 0 9 bar 0 09 MPa Aligning the Vitovalor 300 P 2 1 8x Fig 19 1 Align the fuel cell module flush with the front of the gas condensing module Temporarily reattach the front panel for this purpose see page 44 2 Align the gas condensing module and the fuel cell module in their final installation location Installation...

Page 26: ...in the DHW line as protection against scalding Safety assembly to DIN 1988 and EN 806 on the cold water connection C F B D E GH D K D H L M D N K A O Fig 21 A Safety assembly B Safety valve 10 bar AT 6 bar C Visible discharge pipe outlet point tundish D Shut off valve E Flow regulating valve installation recommended F Pressure gauge connection G Non return valve H Drain K Cold water L Drinking wat...

Page 27: ...sage through the flue gas pipes Flue system with positive pressure is gas tight Apertures for ensuring sufficient combustion air sup ply are open and cannot be closed off Applicable regulations on installing and commission ing flue systems have been followed Danger Leaking or blocked flue systems or an insuffi cient supply of combustion air cause life threat ening poisoning due to carbon monoxide ...

Page 28: ... Fuel cell module to the left of the gas condensing module A B 2 3 1 1 1 2 3 Fig 24 Trim flue pipe B as required Route all horizontal sections of the flue pipe with a constant fall of 3 Connecting the downstream balanced flue Flue system installation instructions Note Only use the System certificate and Skoberne GmbH flue system labels in conjunction with the Viessmann flue system made by Skoberne...

Page 29: ...ll a conden sate removal pump accessories Note Pull the hoses out of the appliance far enough to pre vent unnecessary bends inside the appliance Gas connection A A A Fig 26 The illustration shows all of the connection sets available as accessories A Gas connection R 1 Connect the gas line to gas shut off valve A Installation sequence Installing the Vitovalor 300 P cont 5775 636 GB Installation ...

Page 30: ... cause material damage Remove leak detection agent residues after test ing Please note Excessive test pressure can damage the appliance Max test pressure 150 mbar 15 kPa Where higher pressure is required for tight ness tests disconnect the appliances from the gas supply pipe undo the fitting 3 Vent the gas line Opening the control unit enclosure on the gas condensing module 2x 4x 4 3 5 2 1 Fig 27 ...

Page 31: ...roller B Radio clock receiver Connections to 230 V plugs sK DHW circulation pump or heating circuit pump for heating circuit without mixer Note Connect DHW circulation pumps with standalone functions directly to the 230 V supply lH External demand blocking Connections to LV plugs X3 Plug X3 can be pulled to make assembly easier Outside temperature sensor Flow temperature sensor for low loss header...

Page 32: ...32 Process controller Opening the process controller 1 Fig 29 Installation sequence Electrical connections cont 5775 636 GB Installation ...

Page 33: ...re controller E KM BUS terminals F Power distributor G Power supply fuel cell module H Internal electricity meter K System power supply L Power supply for accessories Information on connecting accessories When connecting accessories observe the sep arate installation instructions provided with them Installation sequence Electrical connections cont 5775 636 GB Installation ...

Page 34: ...onnecting the fuel cell module ensure that ON OFF switch A on the fuel cell module is switched off 0 Connecting the fuel cell module to the process controller BU BN GN GY N L Fig 32 1 Attach connecting cable A to the fuel cell module using the plug provided In its delivered condition the plug is connected to the process controller see diagram below Installation sequence Electrical connections cont...

Page 35: ...ure sensor connection 2 core lead length up to 35 m with a cross section of 1 5 mm2 Note To fit a wireless outside temperature sensor wireless accessories see page 41 External demand via switching contact Connection options EA1 extension accessory see separate installation instructions Plug lH When the contact is closed burner operation is load dependent The boiler water is heated to the set value...

Page 36: ...ts Effect of the function on the circulation pump for cylin der heating Coding address 5F in group DHW 3 External demand via 0 10 V input Connection at 0 10 V input to EA1 extension Please note Ensure DC separation between the earth con ductor and the negative pole of the on site volt age source U L N L N fÖ S P aBJ Ö 0 10V f A Fig 34 0 1 V No default set boiler water temperature 1 V Set value 10 ...

Page 37: ...W 3 Codes Set 3A DE1 3b DE2 or 3C DE3 to 3 or 4 in group General 1 Effect of the function on the heating circuit pump Coding address d6 in group Heating circuit only for weather compensated control units Effect of the function on the circulation pump for cylin der heating Coding address 5E in group DHW 3 Power supply for accessories 230 V 156 156 156 40 X4 8 7 6 5 4 3 2 1 X1 X3 K T6 3 A Fig 35 Pow...

Page 38: ...38 KM BUS connections A Fig 36 Connect the KM BUS on accessories or the KM BUS distributor to terminals A Installation sequence Electrical connections cont 5775 636 GB Installation ...

Page 39: ... gas condensing module If necessary unclip the LAN socket and insert into aperture B on the left or right Power supply to the system Connect the power supply to the system according to the operating mode selected during preparations for installation see page 14 Installation sequence Electrical connections cont 5775 636 GB Installation ...

Page 40: ... regulations Connection requirements specified by your local power supply utility Install an isolator in the power line to provide omnip olar separation from the mains for all active conduc tors corresponding to overvoltage category III 3 mm for complete isolation The isolator must be fitted in the permanent electrical installation in line with installation requirements In addition we recommend th...

Page 41: ...ildings in the upper half of the second floor Not above windows doors or vents Not immediately below balconies or gutters Never render over Wireless repeater accessories For amplifying the wireless signal between the wireless base station in the boiler and the wireless outside tem perature sensor or wireless remote controls Note Required if building characteristics prevent an ade quate signal qual...

Page 42: ...issible tempera ture for these is not exceeded Closing the control unit enclosure 5 4 2 6 2x 3 1 Fig 41 Insert the programming unit packed separately into the control unit support Note The programming unit can also be inserted into a wall mounting base accessories near the boiler Wall mounting base installation instructions Installation sequence Electrical connections cont 5775 636 GB Installation...

Page 43: ...43 Closing the process controller 1 Fig 42 Attach the earth cable to the casing cover Installation sequence Closing the control unit enclosure cont 5775 636 GB Installation ...

Page 44: ...44 3 5 1 2x 2 4 7 6 Fig 43 Installation sequence Fitting the front panels 5775 636 GB Installation ...

Page 45: ...45 Note Residual water may escape during dismantling 1 3 5 4 2x 2 Fig 44 Installation sequence If required for easier handling Dismantling the gas condensing module 5775 636 GB Installation ...

Page 46: ...6 10 9 7 4x 6 8 Fig 45 Note Re insert the serrated lock washer on the right hand side panel when assembling Installation sequence If required for easier handling Dismantling cont 5775 636 GB Installation ...

Page 47: ...47 11 13 12 Fig 46 Installation sequence If required for easier handling Dismantling cont 5775 636 GB Installation ...

Page 48: ...48 14 Fig 47 Installation sequence If required for easier handling Dismantling cont 5775 636 GB Installation ...

Page 49: ...49 15 17 16 Fig 48 Installation sequence If required for easier handling Dismantling cont 5775 636 GB Installation ...

Page 50: ...ing the gas type on the fuel cell module 68 21 Adjusting country settings for grid monitoring on the fuel cell module 69 22 Commissioning the fuel cell module 69 23 Activating start time optimisation 73 24 Ending commissioning mode switching to standard mode 73 25 Linking the fuel cell module and other subscribers in LON 73 26 Checking all connections on the heating water and DHW sides for leaks 2...

Page 51: ...condensing module and connections to the fuel cell module under operating pressure 87 45 Checking the combustion quality 87 46 Checking the flue system for unrestricted flow and tightness 47 Matching the control unit to the heating system 88 48 Adjusting the heating curves 88 49 Calling up and resetting Service on the programming unit of the gas condensing module 90 50 Mounting the cover panel and...

Page 52: ... cell type on type plate A of the fuel cell module and indicate it with on type plate B of the Vitovalor 300 P see fig 49 The following two types can be used FC V75CF1HD FC V75FS1AD Checking the power supply Commissioning inspection maintenance Removing the front panels 5775 636 GB ...

Page 53: ...ess circuit page 70 D DHW Filling the fuel cell module and heating water buffer cylinder Please note Unsuitable fill water increases the level of deposits and corrosion This can cause damage to the appliance The fill and top up water must be softened e g with a small heating water softener Total permissible hardness of the fill and top up water 0 02 mol m3 0 11 dH Antifreeze must not be added to t...

Page 54: ... Fill the fuel cell module via tap C Vent via Air vent valve G at the front of the fuel cell mod ule Air vent valves K at the top of the fuel cell mod ule Note Place a suitable container below air vent valves G and K to catch any fill water that escapes Dry off any moisture that may appear on the fuel cell mod ule 5 Once no more air is escaping through the air vent valves turn tap C to position F ...

Page 55: ...ifreeze suitable for heating systems can be added to the fill water The antifreeze manu facturer must verify its suitability Fill and top up water with a water hardness in excess of the following values must be soft ened e g with a small softening system for heating water Total permissible hardness of the fill and top up water Total heating output Specific system volume kW 20 l kW 20 l kW to 50 l ...

Page 56: ...on and the system will be completely filled 5 If the control unit was already on before filling Switch the control unit ON and activate the fill pro gram see next chapter 6 Close boiler drain fill valve B Activating the filling function Service menu 1 Press OK and å simultaneously for approx 4 s 2 Service functions 3 Filling Filling function is enabled 4 Ending filling function Press OK or ä Filli...

Page 57: ...6 Reconnect drain hose A 7 Check that the condensate pipe is correctly attached to the trap and heat exchanger Note Route the drain hose without any bends and with a constant fall 8 Remount the cover panel 9 Secure the control unit back in the operating posi tion Commissioning inspection maintenance Filling the trap on the gas condensing module with water 5775 636 GB ...

Page 58: ...e required operating pressure has built up close fill valve D Open the shut off valves on the heating water side 7 Remove drain hose B from fill valve C and keep safe Gas condensing module only Switching on mains power and control unit A Fig 55 1 Ensure that ON OFF switch A on the fuel cell module is switched off 0 2 Close the gas shut off valve 3 If the gas condensing module was not already switc...

Page 59: ...sensor as soon as the time and date have been set The display shows Flue gas temp sensor test and Active Note If the flue gas temperature sensor is positioned incor rectly commissioning is cancelled and fault message A3 is displayed see page 132 Venting the heating system 1 Close the gas shut off valve and switch the control unit ON 2 Activate venting program see next chapter Note For function and...

Page 60: ...o the boiler Position the wireless repeater if present at least 1 m away from the control unit and connect to power supply 2 Press OK and å simultaneously for approx 4 s 3 Service functions 4 Wireless 5 Add wireless subscriber 6 When pairing first component only Add with repeater Without wireless repeater NO With wireless repeater YES Note If a wireless repeater subsequently proves neces sary forg...

Page 61: ...ccessful _ _ _ _ and appears on the remote control display Repeat the pairing process 3 Once pairing succeeds enter the 3 digit wireless key on the remote control The wireless key is dis played on the control unit With enter the first digit then confirm with OK Select the next position using and enter the next digit using Confirm each entry with OK 4 Once the wireless key has been fully entered C3...

Page 62: ...st menu point Forgetting wireless components If a faulty component is replaced or the wireless con nection is unstable forget all components including the wireless repeater if installed from the control unit and then re pair them all Forgetting components 1 Call up service menu Press OK and å simulta neously for approx 4 s 2 Service functions 3 Wireless 4 Forget wireless subscriber 5 Yes All wirel...

Page 63: ...gas shut off valve 4 Measure static pressure and record value in the report on page 180 Set value max 25 mbar 2 5 kPa If the set value is exceeded take steps according to the table on page 65 5 Commission the appliance Note During commissioning the boiler can enter a fault state fault EE is displayed because of air in the gas line After approx 5 s press reset R see oper ating instructions to reset...

Page 64: ... connect the pressure gauge 05 Open the gas shut off valve 06 Measure the static pressure Set value max 25 mbar 2 5 kPa 07 If the set value is exceeded take steps according to the table on page 65 08 Close the gas shut off valve remove the pressure gauge tighten the screw in test connector D 09 Open the gas shut off valve Danger Gas escaping from the test connector leads to a risk of explosion Che...

Page 65: ...arts No After approx 51 s fault F9 Check the fan fan connect ing cables power at the fan and fan control Yes Ignition No Fault EE Check ignition module con trol voltage 230 V across plugs X2 1 and X2 2 Check the gas supply Yes Gas train opens No Fault EE Check the gas train control voltage 230 V check the gas supply pressure Yes Ionisation current builds Symbol A No Fault EE Check setting of ionis...

Page 66: ...ing the fuel cell module for commissioning Checking the power supply A Fig 65 1 Check that the power supply has been connected according to the details on page 39 2 Removing the front panel if it is still attached see page 52 3 Ensure that ON OFF switch A on the fuel cell module is switched OFF 0 4 Switch on the power supply at the sub distribution board Programming unit on the fuel cell module Al...

Page 67: ...ust value F No function G Power supply indicator H Fault indicator K Commissioning maintenance indicator L Power generation indicator Note The display switches off when in standard mode economy mode no input has been made for 1 min When a key is pressed the display switches back on Commissioning inspection maintenance Preparing the fuel cell module for commissioning cont 5775 636 GB ...

Page 68: ...le is in Commissioning maintenance operating mode Changing the gas type on the fuel cell module Delivered condition Gas type E Conversion is required only for gas type LL Commissioning maintenance operating mode must be enabled MNT illuminates 1 Select 94 using 2 Press SET to confirm 3 Select gas type E or LL using 4 Press SET to confirm 5 Hold down SET until END and nd are dis played 6 Turn ON OF...

Page 69: ...sing and check the setting made Commissioning the fuel cell module Preparing to fill the process circuit with distilled water Please note Commissioning with non distilled water e g tap water will damage the appliance Fill only with the distilled water supplied or available as an accessory VDE 0510 A B Fig 68 1 Undo the screw and remove the cover from distil led water filler neck A 2 Remove the scr...

Page 70: ...r see page 70 Commissioning mode 1 terminates automatically if power has been generated for 10 hours without inter ruption MNT indicator extinguishes In commissioning mode 3 the fuel cell is filled with distilled water but is not then commissioned If com missioning is to be carried out in full later select commissioning mode 1 The filling process already carried out will then be skipped see page 7...

Page 71: ...re that the integral trap is filled with water Note A fault has occurred during the commissioning process if the display shows alternately End and nP Turn the ON OFF switch on the fuel cell module OFF and then ON again Then restart commission ing mode 1 4 When 05 is displayed under STATE the filling process has finished and the start phase will com mence The starting procedure then continues autom...

Page 72: ...Press SET to complete commissioning mode 3 Note A fault has occurred during the commissioning process if in phase 04 the display shows alter nately End and nP Turn the ON OFF switch on the fuel cell module OFF and then ON again Then restart commission ing mode 3 5 Remove the funnel from the filler neck and secure it to the front panel with the screw see page 69 6 Replace the cover on the distilled...

Page 73: ...anager ON delivered condition or Energy manager OFF See page 86 2 Check that the MNT indicator is lit Depending on the commissioning mode either 11 or 13 will be displayed under ITEM 3 Select 17 using Power generation continues Commissioning mode will be terminated Gas and power supply remain on 4 Press and hold SET until oFF appears under STATE Commissioning mode has terminated when the MNT indic...

Page 74: ... unit must be programmed as fault man ager code 79 1 in the General group The LON subscriber number must be programmed in all control units The LON subscriber list in the fault manager must be up to date Service menu 1 Press OK and simultaneously for approx 4 s 2 Service functions 3 Subscriber check 4 Select subscriber e g subscriber 10 5 Start subscriber check with OK Successfully checked subscri...

Page 75: ...a simple tightness test during the com missioning of your system For this it would be suffi cient to check the CO2 or O2 concentration in the com bustion air at the annular gap of the balanced flue pipe If the CO2 concentration is less than 0 2 or the O2 concentration is greater than 20 6 the flue pipe is deemed to be sufficiently gas tight If actual CO2 values are higher or actual O2 values are l...

Page 76: ...move cables from fan motor A gas train B ignition and ionisation electrode C ignition unit D and earth tab E 4 Undo gas supply pipe fitting F 5 Undo four screws G and remove the burner Please note Prevent damage to the burner Never rest the burner on the burner gauze assembly Commissioning inspection maintenance Removing the burner gas condensing module 5775 636 GB ...

Page 77: ...en remove thermal insulation ring D 3 Undo two Torx screws and remove burner gauze assembly E with gasket F and restrictor G 4 Insert and secure new burner gauze assembly E with new gasket F and restrictor G Torque 5 0 Nm 5 Fit thermal insulation ring D 6 Fit electrodes B Torque 4 5 Nm Commissioning inspection maintenance Checking the burner gasket and burner gauze assembly gas condensing module 5...

Page 78: ...es with a small brush not with a wire brush or sandpaper 3 Check the electrode gaps If the gaps are not as specified or the electrodes are damaged replace the electrodes together with new gaskets and adjust them as required Tighten the electrode fix ing screws with 4 5 Nm Cleaning heating surfaces gas condensing module Please note Scratches to the surfaces of the heat exchanger that come into cont...

Page 79: ...h heating surface A with water 3 Check condensate drain and clean trap See the following chapter 4 Flush the heating surface again with water This will also fill the trap with water Checking condensate drain and cleaning the trap gas condensing module B C A Fig 75 1 Check at the trap that the condensate can drain freely 2 Pull off drain hose A 3 Pull off retaining clip B 4 Remove trap bottle C dow...

Page 80: ...ig 76 1 Insert the burner and tighten screws G crosswise Torque 8 5 Nm 2 Fit gas supply pipe F with a new gasket Torque 30 Nm 3 Check gas connections for tightness Danger Escaping gas leads to a risk of explosion Check the fitting for gas tightness 4 Connect the electrical cables leads Fan motor A Ionisation electrode C Gas train B Ignition unit D Earth E Checking the neutralising system if instal...

Page 81: ... This is required for the following maintenance work The fuel cell module must be in service mode To save time the system user can start service mode in advance It takes about 15 min to drain the distilled water approx 4 5 l B C D E F A Fig 78 Commissioning inspection maintenance Cleaning the air intake on the fuel cell module 5775 636 GB ...

Page 82: ...Under STATE 01 and 02 appear in succes sion The water can be drained when 02 flashes 09 Place a shallow container of sufficient size min 5 l below drain ports B 10 Undo the screw and remove right hand cover C for ventilation 11 Undo the screw in drain port D approx 1 5 turns 12 Remove plug F do not remove screw E 13 When no more water emerges and 04 is flash ing under STATE close openings C D and ...

Page 83: ... and secure with the two screws 13 Reattach the hoses with two clips D 14 Refit trap C with clips A and screw B Resetting the service indicator on the fuel cell module Note If bAD appears on the display the service indicator cannot be reset This may be because the mainte nance interval had not yet been reached for example In such a case inform Viessmann Technical Services 1 Turn on the ON OFF swit...

Page 84: ...ap is filled with water Note A fault has occurred during the commissioning process if the display shows alternately End and nP Turn the ON OFF switch on the fuel cell module OFF and then ON again Then restart commis sioning mode 1 07 When 05 is displayed under STATE the filling process has finished and the start phase will com mence The starting procedure then continues automati cally Phase Durati...

Page 85: ...Check the pre charge pressure of the diaphragm expansion vessel Set value 0 9 bar 0 09 MPa 3 If the charge pressure of the diaphragm expansion vessel is lower than this recharge with nitrogen via connection B 4 Top up with water Observe the specifications for fill and top up water see page 55 Operating pressure 1 0 bar 0 1 MPa Commissioning inspection maintenance 2 yearly maintenance of fuel cell ...

Page 86: ... a higher pressure of 2 or 3 bar 0 2 or 0 3 MPa The safety valve may also respond and discharge the excess pressure Therefore check the expansion vessel pre charge pressure annually Check whether the installed expansion vessel is ade quate for the system water volume GB only Carry out this test on a cold system 1 Drain the system until the pressure gauge shows 0 Alternatively close the cap valve o...

Page 87: ... the following limits for upper and lower heating output respectively 7 5 to 9 5 in the case of natural gas E The O2 content must be between 4 0 and 7 6 for all gas types If the actual CO2 or O2 values lie outside their respec tive ranges proceed as follows check the balanced flue system for tightness see page 75 check the ionisation electrode see page 78 check the connecting cable on the ionisati...

Page 88: ...ching the control unit to the heating system The control unit must be matched to the system equip ment level To do this select the applicable system scheme System examples Set the codes according to the accessories fitted Accessories installation and service instruc tions Note Various system components are recognised automati cally by the control unit and the relevant codes are set automatically F...

Page 89: ...mperature 90 20 26 20 A C D E B Fig 83 Example 1 Adjustment of the standard set room temperature from 20 to 26 C A Boiler water temperature or flow temperature in C B Outside temperature in C C Set room temperature in C D Heating circuit pump OFF E Heating circuit pump ON Changing the standard set room temperature Operating instructions Reduced set room temperature 20 14 5 90 20 D E A C B Fig 84 E...

Page 90: ...r fuel cell 3 OK Gas condensing boiler To display the reason for maintenance Auxiliary heating appliance Acknowledge with Burner OK 05500 h Fig 86 Example Fuel cell module To display the time remaining before a service is due 4 Pressing displays information on the service due Acknowledging and resetting service indicator Press OK to acknowledge a service message Note An acknowledged service messag...

Page 91: ...nstruct the user in oper ating the system This includes all components installed as accessories e g remote control units In addition the system instal ler must make the user aware of the required mainte nance work Commissioning inspection maintenance Instructing the system user 5775 636 GB ...

Page 92: ...ct the coding address 5 Set the value according to the following tables and confirm with OK 6 If you want to reset all codes to their delivered condition Select Standard setting in Coding level 1 Note This also resets codes at coding level 2 General Select General see page 92 Coding Coding in the delivered condition Possible change System design 00 2 One heating circuit without mixer A1 heating ci...

Page 93: ... 0 Apartment building Holiday program and time program for DHW heating can be set sepa rately Lock out controls 8F 0 Operation enabled in standard and extended menu Note The respective code is only ena bled when you exit the service menu 8F 1 Operation locked out in standard and extended menu Emissions test mode can be ena bled 8F 2 Operation enabled in standard menu but locked out in extended men...

Page 94: ... program 73 1 to 73 6 During time program ON for 5 min once an hour up to ON for 5 min six times an hour 73 7 Permanently ON Heating circuit Select Heating circuit see page 92 Coding Coding in the delivered condition Possible change Economy function outside temperature A5 5 With heating circuit pump logic function economy control Heat ing circuit pump OFF when the outside temperature OT is 1 K hig...

Page 95: ... than 20 min Heating circuit pump ON If the mixer changes to control function If there is a risk of frost Pump idle time transition reduced Operation A9 7 With pump idle time heating circuit pump OFF when set value is modified by changing the operating mode or changing the set room temperature A9 0 Without pump idle time A9 1 to A9 15 With pump idle time adjustable from 1 to 15 1 short idle time 1...

Page 96: ... 127 C limited by boiler specific pa rameters Heating program changeover d5 0 With external heating program changeover Observe settings of coding addresses 3A 3b and 3C in General group Operating program switches to constant central heating with re duced room temperature or standby mode depending on the setting of the reduced set room temperature d5 1 Operating program switches to con stant operat...

Page 97: ...nating reduced mode 5 C see example on page 173 Observe setting for coding address A3 F8 10 to F8 60 Temperature limit adjustable from 10 to 60 C F8 61 Function disabled End temperature increase F9 14 Temperature limit for raising the set reduced room temperature 14 C see example on page 173 F9 10 to F9 60 Temperature limit for raising the set room temperature to the value se lected for standard m...

Page 98: ... value according to the following tables and confirm with OK 7 If you want to reset all codes to their delivered condition Select Standard setting in Coding level 2 Note This also resets codes at coding level 1 General Select General see page 98 Coding Coding in the delivered condition Possible change 00 2 One heating circuit without mixer A1 heating circuit 1 00 4 to 00 10 For system schemes see ...

Page 99: ... 0 Function of output aBJ at EA1 ex tension Fault message 36 1 Feed pump 36 2 DHW circulation pump 39 0 Function of output sK DHW circu lation pump 39 1 Function of output sK Heating cir cuit pump 39 2 Function of output sK Circulation pump for cylinder heating 3A 0 Function of input DE1 at EA1 ex tension No function 3A 1 Heating program changeover 3A 2 External demand with set flow tem perature S...

Page 100: ...n this group 3C 4 External blocking with fault message input Internal circulation pump function Coding address 3E in this group 3C 5 Fault message input 3C 6 Brief operation of DHW circulation pump keypad function Adjusting DHW circulation pump runtime Coding address 3d in this group 3d 5 Runtime of DHW circulation pump during brief operation 5 min 3d 1 to 3d 60 Runtime of DHW circulation pump adj...

Page 101: ... subscriber number adjustable from 1 to 99 1 4 Boiler 27 Fuel cell module 28 97 Vitotronic 200 H 98 Vitogate 99 Vitocom 79 1 Control unit for weather compen sated operation with LON commu nication module Control unit is fault manager 79 0 Control unit is not fault manager 7b 1 Control unit for weather compen sated operation with LON commu nication module Control unit transmits the time 7b 0 No tim...

Page 102: ... 97 0 With LON communication module The outside temperature of the sensor connected to the control unit is used internally 97 1 The control unit receives the outside temperature 97 2 The control unit sends the outside temperature to the Vitotronic 200 H 98 1 With LON communication module Viessmann system number in con junction with monitoring several systems via Vitocom 300 98 1 to 98 5 System num...

Page 103: ... No service interval set in hours run 21 1 to 21 100 The number of hours run before the burner should be serviced is adjust able from 100 to 10 000 h One adjusting step 100 h 23 0 No time set for burner service in terval 23 1 to 23 24 Interval adjustable from 1 to 24 months 24 0 Service not shown on the dis play 24 1 Service shown on the display The address is set automatically and must be reset m...

Page 104: ... adjustable from 5 to 25 K 62 2 Circulation pump with 2 min run on time after cylinder heating 62 0 No circulation pump run on 62 1 to 62 15 Run on time adjustable from 1 to 15 min 65 Never adjust Information on type of diverter valve defaulted by the coding card 6C 100 Set speed of internal circulation pump for DHW heating 100 6C 0 to 6C 100 Set speed adjustable from 0 to 100 6F Max heating outpu...

Page 105: ...automatically A1 0 All settings available on the remote control can be carried out A1 1 Only on Vitotrol 200 Only party mode can be set at the remote control A3 2 Outside temperature below 1 C Heating circuit pump ON Outside temperature above 3 C Heating circuit pump OFF A3 9 to A3 15 Heating circuit pump ON OFF see the following table Please note With settings below 1 C there is a risk that pipes...

Page 106: ...the delivered condition Possible change A6 36 Extended economy mode disa bled A6 5 to A6 35 Extended economy mode enabled The burner and heating circuit pump will stop at a variable value adjusta ble between 5 and 35 C plus 1 C Mixer is being closed Basis for this is the adjusted outside temperature This is composed of the actual out side temperature and a time con stant that takes account of the ...

Page 107: ...perature de pendent heating circuit pump logic function b5 1 to b5 8 Heating circuit pump logic function see the following table Parameter address b5 With heating circuit pump logic function Heating circuit pump OFF Heating circuit pump ON 1 RTactual RTset 5 K RTactual RTset 4 K 2 RTactual RTset 4 K RTactual RTset 3 K 3 RTactual RTset 3 K RTactual RTset 2 K 4 RTactual RTset 2 K RTactual RTset 1 K ...

Page 108: ...ops on signal External demand depending on coding addresses 3A 3b and 3C d8 0 With EA1 extension No operating program changeover d8 1 Operating program changeover via input DE1 d8 2 Operating program changeover via input DE2 d8 3 Operating program changeover via input DE3 E1 1 Never adjust E2 50 With remote control No display correction for the actual room temperature only for weath er compensated...

Page 109: ... pushbutton 8 h 1 Note Observe settings of coding ad dresses 3A 3b and 3C in group General and d5 and d8 in group Heating circuit F2 0 No time limit 1 F2 1 to F2 12 Time limit adjustable from 1 to 12 h 1 F8 5 Temperature limit for terminating reduced mode 5 C see example on page 173 Observe setting for coding address A3 F8 10 to F8 60 Temperature limit adjustable from 10 to 60 C F8 61 Function dis...

Page 110: ...rcuit 1 HC1 Heating circuit 2 HC2 Heating circuit 3 HC3 DHW Brief scan Reset data Actuator test Coding level 1 Coding level 2 Fault history Service functions Subscriber check Service PIN Enter Vitocom PIN code Wireless Service indicator reset Filling Venting Max heating output Reset fuel cell Terminate service Note Do not adjust menu point Multi boiler system The menu point changes the function of...

Page 111: ...sions and connected components for example 1 Press OK and å simultaneously for approx 4 s 2 Diagnosis 3 Brief scan 4 Press OK The display shows 9 lines with 6 fields each Diagnosis brief scan 2 1 3 4 Select with Ø 0 0 0 0 4 0 0 0 0 0 0 0 A 0 0 0 0 0 0 1 2 0 0 0 Fig 87 For an explanation of the relevant values in the individual rows and fields see the following table Row brief scan Field 1 2 3 4 5 ...

Page 112: ...ng circuit M3 0 No mixer extension 0 Checking outputs actuator test 1 Press OK and å simultaneously for approx 4 s 2 Actuator test The following relay outputs can be controlled subject to the system equipment level Display Explanation All actuators OFF All actuators have been switched off Base load ON Burner operates at min output Internal pump is switched on Full load ON Burner operates at max ou...

Page 113: ... A2 at AM1 extension enabled EA1 output 1 ON Contact P S at plug aBJ of EA1 extension closed System separation pump ON Output 173 on differential temperature controller CU 125 enabled Fuel cell module Calling up power generated Operating instructions for Vitovalor 300 P Calling up operating condition Operating instructions for Vitovalor 300 P Calling up grid monitoring parameters GEN MNT ERR GRD D...

Page 114: ...se time 81 Min voltage 184 V 200 s 82 Max voltage 253 V 600 s 83 Max voltage 264 5 V 200 ms 84 Min frequency 47 5 Hz 200 ms 85 Max frequency 51 5 Hz 200 ms Resetting fuel cell module data The following statistical data from the fuel cell module can be reset Power generated CO2 reduction Gas consumption history Extended menu 1 2 Service 3 Service functions 4 Reset fuel cell data Diagnosis and servi...

Page 115: ...s are sorted by date Service menu 1 Press OK and å simultaneously for approx 4 s 2 Fault history 3 Display Delete fault history Service menu 1 Press OK and å simultaneously for approx 4 s 2 Fault history 3 Delete Fault codes for gas condensing module Fault code dis played System characteristics Cause Measures 0F Control mode Service 0F is only displayed in the fault history Service the appliance N...

Page 116: ... temper ature sensor heating cir cuit 3 with mixer Check flow temperature sensor 48 Mixer being closed Lead break flow tempera ture sensor heating circuit 2 with mixer Check flow temperature sensor 4C Mixer being closed Lead break flow tempera ture sensor heating circuit 3 with mixer Check flow temperature sensor 50 No DHW heating Short circuit cylinder tem perature sensor Check cylinder temperatu...

Page 117: ...in the internal circula tion pump or minimum flow rate not achieved Vent the system if the fault mes sage persists A9 If a heating circuit with mixer is connected the burner op erates at its lower heating output If only one heating circuit without mixer is connected the burner is blocked Internal circulation pump blocked Check circulation pump b0 Burner blocked Short circuit flue gas tem perature ...

Page 118: ...remote controls Check connection place remote control close to the boiler bF Control mode Incorrect LON communi cation module Replace LON communication mod ule C1 Control mode Communication error EA1 extension Check connections Without extension EA1 Set code 5b 0 in General group C2 Control mode Communication error so lar control module Check solar control module C3 Control mode Communication erro...

Page 119: ...ixer Check room temperature sensor heating circuit 1 and remote control configuration see page 175 dE Control mode without room influence Lead break room temper ature sensor heating cir cuit 2 with mixer Check room temperature sensor heating circuit 2 and remote control configuration see page 175 dF Control mode without room influence Lead break room temper ature sensor heating cir cuit 3 with mix...

Page 120: ...pen flue operation prevent high levels of dust in the combus tion air Press reset R Following several unsuccessful re set attempts replace the coding card and press reset R Eb Burner in a fault state Repeated flame loss dur ing calibration Check gap between ionisation electrode and burner gauze as sembly see page 78 Check flue system remove flue gas recirculation if required Press reset R EC Burne...

Page 121: ...le Press reset R F7 Burner blocked Short circuit or lead break water pressure sensor Check the water pressure sensor and lead F8 Burner in a fault state Fuel valve closes too late Check gas train Check both con trol paths Press reset R F9 Burner in a fault state Fan speed too low during burner start Check fan fan connecting cables and power supply to fan check fan control Press reset R FA Burner i...

Page 122: ...layed in plain text For an explanation of the fault code see the following pages Acknowledging fault Follow the instructions on the display Note The fault message is transferred to the standard menu Any fault message facility connected will be switched off If an acknowledged fault is not remedied the fault message will be redisplayed the following day and the fault message facility restarted Calli...

Page 123: ...as supply interrup ted Check gas supply Other fault mes sages Inform Viessmann Technical Services Repairs gas condensing module Putting the control unit into the service position If required for commissioning and servicing the control unit can be put into a different position 1 3 2 4 Fig 91 Draining the system on the heating water and DHW sides Only when necessary for repair work Troubleshooting F...

Page 124: ... A Draining the heating water buffer cylinder Fig 93 1 Check that the fuel cell module is switched off 2 Connect the hose to the drain valve and route it into a suitable container or drain outlet 3 Turn the lever on the drain valve to position C Note This will not drain the process circuit of the fuel cell module See page 81 Troubleshooting Repairs gas condensing module cont 5775 636 GB Diagnosis ...

Page 125: ... min Please note If this waiting time is not observed there is a risk of scalding and damage to the appliance 2 Place a shallow container of sufficient size min 5 l below drain port A 3 Unscrew the filter from drain port A 4 Undo screw B approx 1 5 turns Draining the system on the DHW side B A Fig 95 1 Shut off the cold water connection Troubleshooting Repairs gas condensing module cont 5775 636 G...

Page 126: ...ance in kΩ Fig 97 Sensor type NTC 10 kΩ 1 Pull plug X3 from the control unit 2 Test the resistance of the outside temperature sen sor across terminals X3 1 and X3 2 on the dis connected 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 the test on the sensor itself 4 Depending on the result replace the lead...

Page 127: ...ylinder temperature sensor Pull plug from the cable harness at the control unit and check resistance Flow temperature sensor Pull plug X3 at the control unit and check resist ance across terminals X3 4 and X3 5 2 Compare the sensor resistance with the curve 3 In the event of severe deviation replace the sensor Danger The boiler water temperature sensor is directly immersed in the heating water ris...

Page 128: ...ll leads from outlet temperature sensor A 2 Check sensor resistance and compare it to the curve 3 In the event of severe deviation replace the sensor Danger The outlet temperature sensor is directly immersed in the DHW risk of scalding Drain the DHW side of the boiler before replacing the sensor Troubleshooting Repairs gas condensing module cont 5775 636 GB Diagnosis ...

Page 129: ...om return temperature sensor A 2 Check sensor resistance and compare it to the curve 3 In the event of severe deviation replace the sensor Danger The return temperature sensor is in direct contact with the heating water risk of scald ing Drain the boiler on the heating water side before replacing the sensor Troubleshooting Repairs gas condensing module cont 5775 636 GB Diagnosis ...

Page 130: ...l plug A or B from the differential tempera ture controller 2 Check sensor resistance and compare it to the curve 3 In the event of severe deviation replace the sensor Checking the plate heat exchanger Note During and after removal small amounts of water may trickle from the plate heat exchanger Troubleshooting Repairs gas condensing module cont 5775 636 GB Diagnosis ...

Page 131: ...ng forwards 6 Check the connections on the heating water and DHW side for soiling and scaling if required replace the plate heat exchanger 7 Install in reverse order using new gaskets Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler if the permissible flue gas temperature is exceeded Reset the interlock after the flue system has cooled down by pressing ...

Page 132: ...uring commissioning the control unit checks whether the flue gas temperature sensor is correctly positioned If the flue gas temperature sensor is not positioned correctly commissioning is cancelled and fault mes sage A3 is displayed 1 Check whether the flue gas temperature sensor is correctly inserted See previous diagram 2 If necessary correct the position of the flue gas temperature sensor or re...

Page 133: ... boiler water temperature is below approx 75 C check the following A Fig 109 1 Pull leads from temperature limiter A 2 Check continuity of the temperature limiter with a multimeter 3 Remove faulty temperature limiter 4 Coat the new temperature limiter with heat con ducting paste and install it 5 After commissioning press reset R on the control unit Troubleshooting Repairs gas condensing module con...

Page 134: ...ements a self test During this the mixer is opened and closed again Note The mixer motor can also be started via the actuator test see chapter Checking outputs Observe the rotational direction of the mixer motor dur ing its self test Then manually set the mixer back to Open The flow temperature sensor must now capture a higher temperature If the temperature drops either the motor is turning in the...

Page 135: ...onnect plug flow temperature sensor 2 Check the sensor resistance and compare it to the curve In the event of severe deviation replace the sensor Checking the Vitotronic 200 H accessories The Vitotronic 200 H is connected to the control unit via the LON cable To test the connection carry out a subscriber check at the boiler control unit see page 74 Troubleshooting Repairs gas condensing module con...

Page 136: ...136 Troubleshooting Repairs gas condensing module cont 5775 636 GB Diagnosis ...

Page 137: ... part within the assembly from this parts list A B C D E F G H K L M N Fig 113 A Type plate B Casing C Heat cell D Burner E External connection F Heat cell hydraulics G Buffer cylinder H DHW cylinder K Miscellaneous L Vitovalor VBC 132 control unit M Vitovalor VUC 170 control unit N Fuel cell Parts lists Overview of assemblies 5775 636 GB Components ...

Page 138: ...001 0001 0008 0003 __ 0006 0003 __ __ 0009 0012 0016 0013 __ 0003 0010 0003 __ 0007 0006 0002 0005 0015 0005 0005 0005 0005 0004 0014 0011 0003 0003 0003 0003 Fig 114 Parts lists Casing assembly 5775 636 GB Components ...

Page 139: ...ogo 0007 Side panel left PLB 0008 Side panel right PLB 0009 Front panel top PLB 0010 Front panel bottom PLB 0011 Retainer for side panel right PLB 0012 Control unit support 0013 AC meter mounting plate 0014 Mounting plate for process control unit 0015 Cover panel with gaskets 0016 AC meter ALD1 32A Parts lists Casing assembly cont 5775 636 GB Components ...

Page 140: ...014 0038 0014 __ 0014 __ 0039 0014 0014 0014 __ 0017 0025 0018 0024__ 0012 0014 0049 0008 0023 0049 0023 0020 0008 __ __ __ 0010 0031 0020 0008 0011 0031 __ __ 0032 0005 0021 0038 0013 0030 0001 0026 0014 0009 0008 0006 __ __ __ __ __ 0036 0026 0014 0009 0008 0006 0033 __ __ __ __ __ 0004 0011 0019 __ 0007 0019 0047 0048 __ __ __ __ 0045 0007 0046 0007 __ __ 0046 0007 0043 0047 0048 0019 0007 0007...

Page 141: ...rommet DG36 14 0023 Thermal insulation block 0024 Hose clip 34 37 4 0025 Spring clip condensate drain 0026 Gasket A 17 x 24 x 2 5 pce 0027 Flow sensor 0028 Safety valve 3 bar 0029 Gasket A 23 x 30 x 2 5 pce 0030 Condensate hose 0031 Plug for boiler flue connection 0032 Boiler flue connection 7 60 100 anthracite 0033 Connection piece 0034 Balanced flue pipe 7 80 125 l 250 0035 Tee 7 60 100 7 80 125...

Page 142: ...47 Inspection bend cover with gasket 7 80 125 0048 Inspection cover internal bend 7 60 0049 Felt strip 100 x 50 x 2 2 pce 0050 Pipe clip 7 18 0051 Air vent valve G 3 8 0052 Hose 10 x 1 5 x 1500 Parts lists Heat cell assembly cont 5775 636 GB Components ...

Page 143: ...143 Parts lists Heat cell assembly 5775 636 GB Components ...

Page 144: ... 0007 0006 0021 0020 0010 0020 0001 0014 0026 0013 0017 0003 0003 0001 0025 0005 0007 0008 0001 0015 0003 0023 0003 0003 0003 0009 0011 0012 0003 0003 0003 0003 0009 0009 0028 0009 0011 0003 0024 0022 0027 0011 Fig 116 Parts lists Burner assembly 5775 636 GB Components ...

Page 145: ...nturi extension 0011 Seal ring 38 x 44 x 3 5 pce 0012 Pipe clip 7 18 1 5 0013 Gas nozzle 04 grey 0014 Ignition unit 0015 Burner gasket 7 187 0016 Mixture restrictor 0017 Gas train CES10 0018 Thermal insulation ring 0019 Mounting plate thermal insulation ring 2 pce 0020 Gasket DN 65 0021 Ionisation electrode 0022 Gas supply pipe 0023 Locknut M 32 x 1 5 0024 Gas pipe 0025 Burner door 0026 Radial fan...

Page 146: ...17 0014 0012 0011 0009 0007 __ __ __ __ __ __ __ __ 0024 0014 0009 0029 0017 0007 0022 0006 0013 0009 0007 __ __ 00019 0006 0004 0015 0031 0010 0007 0006 0005 0004 0002 0021 __ __ __ __ __ __ __ 0028 0011 0007 __ __ 0001 0004 0011 0012 __ __ __ __ 0011 0026 0003 0012 0004 0015 0011 0001 0008 0017 0030 0017 0017 0009 0017 __ __ 0025 Fig 117 Parts lists Heat cell hydraulic assembly 5775 636 GB Compo...

Page 147: ...17 Gasket A 23 x 30 x 2 5 pce 0018 Corrugated connection pipe DHW pre heating 0019 Corrugated connection pipe cold water buffer cylinder 0020 Connection pipe DHW buffer cylinder 0021 Connection pipe heating water flow 0022 Connection pipe heating water return 0023 Plate heat exchanger 0024 Aquablock 0025 Aquablock thermal insulation 0026 Fitting cube 0027 Safety valve female connection 0028 System...

Page 148: ...148 0001 0001 0003 0003 0002 0002 0004 Fig 118 Parts lists External connection assembly 5775 636 GB Components ...

Page 149: ...149 Pos Part 0001 Tee 0002 Gasket A 17 x 24 x 2 5 pce 0003 Gasket A 10 x 15 x 1 5 5 pce 0004 Corrugated pipe back heat exchanger Parts lists External connection assembly cont 5775 636 GB Components ...

Page 150: ...__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ 0017 0018 0014 0014 0019 0003 0016 0021 0022 0004 0010 0004 0020 0015 0015 0024 0004 0007 0006 0006 0005 0005 0003 0007 0004 0013 0002 0002 0001 0008 0008 0008 0008 0008 0012 0019 0014 0013 0007 0004 0003 0002 __ __ __ __ __ __ __ 0023 __ __ __ Fig 119 Parts lists Buffer cylinder assembly 5775 636 GB Components ...

Page 151: ...off elbow G 3 4 AG G 3 4 0011 Cap G 3 4 0012 Insulation 0013 Gasket A 23 x 30 x 2 5 pce 0014 Wire clip 5 pce 0015 Flow return pipe 0016 Cylinder 0017 Cylinder temperature sensor NTC L 2000 blue 0018 Cylinder temperature sensor NTC L 1750 red 0019 Push fit connector plug 0020 Hose nozzle 1 2 with union nut G 3 4 0021 Mounting plate corrugated pipe 0022 Corrugated connection pipe buffer cylinder 002...

Page 152: ...03 0008 0008 0009 0009 0018 0018 0016 0007 0006 0002 0007 0007 0002 0010 0014 0006 0005 0004 0013 0005 0014 0004 0015 0017 0010 0006 0006 0006 0011 0012 0001 Fig 120 Parts lists DHW cylinder assembly 5775 636 GB Components ...

Page 153: ... 5 pce 0008 Protective profile 0009 Hose clip 7 340 360 x 9 perforated 0010 Cylinder with thermal insulation 0011 Cylinder insulation EPS front 0012 Cylinder insulation EPS back 0013 Pipe clip 7 18 0014 Wire clip 5 pce 0015 Cap anthracite DHW cylinder 0016 Corrugated connection pipe DHW cylinder 0017 Connection pipe DHW drain 0018 Profile gasket 4 pce Parts lists DHW cylinder assembly cont 5775 63...

Page 154: ...154 0006 0003 0005 0001 0002 0004 Fig 121 Parts lists Miscellaneous assembly 5775 636 GB Components ...

Page 155: ...ns 0002 Installation and service instructions 0003 Heat conducting paste 0004 Touch up spray paint Vitosilver 150 ml can 0005 Touch up paint stick Vitosilver 0006 Special grease Parts lists Miscellaneous assembly cont 5775 636 GB Components ...

Page 156: ...5 0005 0008 0015 0014 0027 0003 0015 0018 0017 0005 0004 0002 0008 0001 0015 0006 0010 0011 0012 0020 0026 0024 0023 0022 0021 Fig 122 Parts lists Vitovalor VBC 132 control unit assembly 5775 636 GB Components ...

Page 157: ...Molex stepper motor 0014 Cable tie 10 pce 0015 Locking bolts left and right 0017 Wireless outside temperature sensor 0018 Outside temperature sensor NTC 0020 Connecting cable D5 0021 Connecting cable 145 KM BUS internal 0022 KM BUS connecting cable 145 0023 Connecting cable meter 0024 Lead return temperature sensor 17 0025 LAN coupling with cable 0026 Patch cable 2 m 0027 Internal H1 extension Par...

Page 158: ...158 0016 0005 0004 0002 0001 0015 0014 0013 0012 0011 0010 0009 0008 0007 0006 0015 0003 Fig 123 Parts lists Vitovalor VUC 170 control unit assembly 5775 636 GB Components ...

Page 159: ... PCB distribution board with fuse 0006 Power cable power supply unit 0007 Lead 40 156 0008 Lead 40 0009 LAN coupling with lead 2 m 0010 Connecting cable EM 300 0011 LON cable 7 m 0012 Plug 40 0013 Cable clip WS 3 01 5 pce 0014 Individual Vitovalor cables 0015 Control unit enclosure 0016 Power supply plug fuel cell Parts lists Vitovalor VUC 170 control unit assembly cont 5775 636 GB Components ...

Page 160: ...160 Parts not shown 0009 PCB IU100 B30 Parts lists Fuel cell assembly 5775 636 GB Components ...

Page 161: ...161 Parts lists Fuel cell assembly cont 5775 636 GB Components ...

Page 162: ...162 0005 0004 0001 0004 0005 0006 0007 0002 0003 0008 0004 Fig 124 Parts lists Fuel cell assembly cont 5775 636 GB Components ...

Page 163: ... 3 phase meter with M Bus not for GB 0003 Front panel fuel cell 0004 Location stud 2 pce 0005 Panasonic logo 0006 Distilled water filter element 0007 Air filter 0008 Bi annual maintenance pack Parts lists Fuel cell assembly cont 5775 636 GB Components ...

Page 164: ...perature is reached The loading cylinder is heated up to the set cylinder temperature Heating stops when the specified temper ature has been reached at the cylinder temperature sensor After loading has stopped the cylinder loading pump and the 3 way diverter valve remain on for a further 30 s Operating the fuel cell module The fuel cell module is switched to power generation according to the heat ...

Page 165: ...has ended the loading cylin der continues to be heated up until the set DHW tem perature has been reached at the cylinder temperature sensor The cylinder loading pump and the 3 way diverter valve remain ON for a further 30 s Boosting DHW heating This function is activated by specifying a second set DHW temperature via coding address 58 in group DHW and activating the fourth DHW phase for DHW heati...

Page 166: ... unit enclosure in place of internal H1 extension Con nect the internal cylinder loading pump to relay output sK An extractor fan can be switched off via connection aBJ when the burner starts Function description Internal H2 extension accessories 5775 636 GB Functions ...

Page 167: ...ion pump for cylinder heating DHW circulation pump Connect DHW circulation pumps with standalone functions directly to the 230 V supply Select the output functions via the codes on the boiler control unit Function assignment Function Code General group Output A1 Output A2 DHW circulation pump sK 33 0 34 0 delivered condition Heating circuit pump sÖ 33 1 delivered condition 34 1 Circulation pump fo...

Page 168: ...ust be potential free When making the connection adhere to the requirements of protec tion class II 8 0 mm air and creep paths and 2 0 mm insulation thickness against live components Input function assignment Select the input functions via the codes in the Gen eral group at the boiler control unit DE1 Coding address 3A DE2 Coding address 3b DE3 Coding address 3C Assigning the operating program cha...

Page 169: ...erature 0 1 V is taken as no set boiler water temperature default 1 V Set value 10 C 10 V Set value 100 C Ensure DC separation between the earth conductor and the negative pole of the on site power source Output aBJ The following functions can be connected to output aBJ Feed pump to substation or DHW circulation pump or Fault message facility Information regarding the feed pump Function only possi...

Page 170: ...g as the duration selected in coding address F2 External blocking The functions External blocking and External block ing and fault message input are implemented via the EA1 extension There are 3 inputs available at the EA1 extension DE1 to DE3 The function is selected via the following coding addresses in the General group External blocking Code Input DE1 3A 3 Input DE2 3b 3 Input DE3 3C 3 Externa...

Page 171: ...n be filled com pletely Filling with the control unit switched on If the system is to be filled with the control unit switched on the diverter valve is moved to its central position in the fill program and the pump starts When the function is enabled the burner shuts down The program automatically becomes inactive after 20 min Screed drying When activating screed drying observe the informa tion pr...

Page 172: ...s 50 40 30 20 10 1 5 10 15 20 25 30 Fig 131 Temperature profile 3 Code F1 3 Flow temperature C Days 50 40 30 20 10 1 5 10 15 20 25 30 Fig 132 Temperature profile 4 Code F1 4 Flow temperature C Days 50 40 30 20 10 1 5 10 15 20 25 30 Fig 133 Temperature profile 5 Code F1 5 Flow temperature C 1 5 10 15 20 25 30 Days 50 40 30 20 10 Fig 134 Function description Control functions cont 5775 636 GB Functi...

Page 173: ...eration at reduced room temperature the reduced set room temperature can be automatically raised subject to the outside temperature The temper ature is raised in accordance with the selected heating curve and no higher than the set standard room tem perature The outside temperature limits for the start and end of temperature raising can be set in coding addresses F8 and F9 in the Heating circuit g...

Page 174: ...rature Reducing the heat up time During the transition from operation with reduced room temperature to operation with standard room tempera ture the boiler water or flow temperature is raised in accordance with the selected heating curve The boiler water or flow temperature increase can be automati cally raised The value and duration for the additional increase of the set boiler water or flow temp...

Page 175: ...eating circuit assignment must be configured when commissioning the Vitotrol Heating circuit Vitotrol configuration 200 A 200 RF 300 A 300 RF The remote control affects the heating circuit without mixer A1 H 1 HC 1 The remote control affects the heating circuit with mixer M2 H 2 HC 2 The remote control affects the heating circuit with mixer M3 H 3 HC 3 One heating circuit can be assigned to the Vi...

Page 176: ...ratio is determined using the actual values The correlation between CO2 or O2 content and air ratio λ is shown in the following table Air ratio λ CO2 O2 content Air ratio λ O2 content CO2 content 1 20 3 8 9 6 1 24 4 4 9 2 1 27 4 9 9 0 1 30 5 3 8 7 1 34 5 7 8 5 1 37 6 1 8 3 1 40 6 5 8 1 1 44 6 9 7 8 1 48 7 3 7 6 To achieve optimum combustion control the system regularly carries out an automatic sel...

Page 177: ...sor plug on cable har ness aA Ionisation electrode aG Flue gas temperature sensor dÖ Stepper motor for diverter valve fJ Thermal circuit breaker gF Ignition unit a Ö Fan motor a ÖA Fan motor control a Ö Modulation coil A Flow sensor Connection and wiring diagram Connection diagram internal gas condensing module 5775 636 GB Appendix ...

Page 178: ...terfaces Outside temperature sensor Flow temperature sensor low loss header Cylinder temperature sensor plug on cable har ness sÖ Internal circulation pump sA Cylinder loading pump sK DHW circulation pump or heating circuit pump for heating circuit without mixer dG Gas solenoid valve fÖ Power supply lH Switched power outlet a Ö Fan motor a ÖA Fan motor control aYA Gas pressure switch aVG KM BUS Co...

Page 179: ... Buffer temperature sensor top B Buffer temperature sensor bottom aJ Return temperature sensor fÖ Power supply aVG KM BUS aMD Circulation pump for buffer discharge Connection and wiring diagram Differential temperature controller 5775 636 GB Appendix ...

Page 180: ...r natural gas At lower heating output by vol 7 5 9 5 At upper heating output by vol 7 5 9 5 Oxygen content O2 At lower heating output by vol 4 0 7 6 At upper heating output by vol 4 0 7 6 Carbon monoxide content CO At lower heating output ppm 1000 At upper heating output ppm 1000 Fuel cell module Electrical output W 750 Power generated kWh Amount of gas consumed m3 Hours run h Distilled water filt...

Page 181: ...g output range for DHW heating kW 6 9 29 3 Rated heating input range kW 7 2 30 5 2 0 Output el W 750 Power consumption In the delivered condition W 80 Maximum W 150 1250 Standby W 5 10 Supply values relative to the max load Natural gas E m3 h 3 23 0 22 Natural gas LL m3 h 3 75 0 25 Heating water buffer cylinder capacity l 170 DHW cylinder capacity l 46 Product ID CE 0085CP0028 Note The supply valu...

Page 182: ...tem are not part of ordi nary household waste For decommissioning the system isolate the system from the power supply and allow components to cool down where appropriate All components must be disposed of correctly Disposal Final decommissioning and disposal 5775 636 GB Appendix ...

Page 183: ...is prod uct is designated CE 0085 811 2013 2009 125 EC 813 2013 2009 142 EC 2004 108 EC 2010 30 EU 2006 95 EC Allendorf 04 January 2016 Viessmann Werke GmbH Co KG Authorised signatory Manfred Sommer Manufacturer s certificate according to the 1st BImSchV Germany We Viessmann Werke GmbH Co KG D 35107 Allendorf confirm that the product Vitovalor 300 P type C3TB complies with the NOx limits specified...

Page 184: ...with 70 Distilled water cartridge replacing 82 Domestic distribution box 16 17 18 19 Drain lines routing 29 E Electronic combustion controller 176 Energy manager 86 Energy meter 14 Excess export 18 19 Excess export system 15 Extension AM1 167 EA1 168 Internal H1 165 Internal H2 166 Extension kit for heating circuit with mixer 134 External blocking 170 External demand 170 External meter registering...

Page 185: ...16 17 18 19 Protective devices 21 R Raising reduced room temperature 173 RCD 20 21 Reduced set room temperature 89 Reducing heat up output 173 Reducing heat up time 174 Relay test 112 Remote control 175 Removing a fault display 115 Removing the front panels 52 Report 180 Reset data fuel cell 114 Resetting codes 92 98 Response characteristics 21 Response times 21 Return temperature sensor 129 Rotat...

Page 186: ...8 Venting program 171 Vitocom 73 Vitotronic 200 H 135 W Water circuits 53 Wireless accessories Forgetting 62 Pairing 60 Wireless components installing 41 Wiring diagram 177 Keyword index Keyword index cont 5775 636 GB ...

Page 187: ...187 5775 636 GB ...

Page 188: ...ood 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 5775 636 GB Subject to technical modifications ...

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Viessmann C3TB, Installation And Service Instructions For Contractors

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