Viessmann VITODENS 300-W Service Manual Download Page 1

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VIESMANN

Service instructions

for contractors

Vitodens 300-W
Type WB3C

, 3.8 to 35.0 kW

Wall mounted gas fired condensing boiler
Natural gas and LPG version

For applicability, see the last page

VITODENS 300-W

5692 673 GB

5/2008

Please keep safe.

Summary of Contents for VITODENS 300-W

Page 1: ...ructions for contractors Vitodens 300 W Type WB3C 3 8 to 35 0 kW Wall mounted gas fired condensing boiler Natural gas and LPG version For applicability see the last page VITODENS 300 W 5692 673 GB 5 2...

Page 2: ...legal instructions regarding the prevention of accidents all legal instructions regarding environmental protection the Code of Practice of relevant trade associations all current safety regulations a...

Page 3: ...loads Repair work Please note Repairing components which fulfil a safety function can com promise the safe operation of your heating system Replace faulty components only with original Viessmann spare...

Page 4: ...s 82 Function description Constant temperature control unit 89 Weather compensated control unit 90 Extensions for external connections accessories 93 Control functions 96 Remote control DIP switches 1...

Page 5: ...hecking the gas type 11 10 Gas type conversion only for operation with LPG 12 11 Function sequence and possible faults 12 12 Checking the static and supply pressure 14 13 Setting the maximum output 15...

Page 6: ...25 Checking the combustion quality 22 26 Checking the external LPG safety valve if installed 27 Matching the control unit to the heating system 23 28 Adjusting the heating curves only for weather comp...

Page 7: ...of the dia phragm expansion vessel 2 Close the gas shut off valve 3 Fill the heating system via the boil er fill drain valve A in the heat ing return at the connection set or on site Minimum system pr...

Page 8: ...valves A and B and vent at mains pressure until no sound of escaping air can be heard 4 Close valves A and B and open the heating water shut off valves Venting the heating system 1 Close the gas shut...

Page 9: ...ng program runs the display shows EL constant temperature control unit or Entl f tung Venting weather compen sated control unit 3 Check the system pressure Filling the siphon with water 1 Remove retai...

Page 10: ...g keys 1 a b for the current time 2 d to confirm Datum is dis played 3 a b for the current date 4 d to confirm Selecting the language if required only for weather com pensated control units Note When...

Page 11: ...ge 10 0 to 16 1 kWh m3 36 0 to 58 0 MJ m3 Convert the burner for operation with LPG see Gas type conversion on page 12 1 Determine the gas type and Wobbe index by asking your local gas sup ply utility...

Page 12: ...1 operation with LPG Set code 11 9 Terminate code 2 4 Open the gas shut off valve Function sequence and possible faults Display screen Measures Control unit is sues heat de mand No Increase set value...

Page 13: ...and the gas pipe for air locks Yes Burner in opera tion No Stops below the set boiler water temperature and restarts immedi ately Check the flue gas system for soundness flue gas recirculation check t...

Page 14: ...vent the tank and gas supply lines after flushing 1 Close the gas shut off valve 2 Release screw A inside test con nector PE on the gas train but do not remove it then connect the pressure gauge 3 Ope...

Page 15: ...ly flow pressure for nat ural gas Supply flow pressure for LPG Measures below 17 4 mbar below 42 5 mbar Do not start the boiler Notify your mains gas or LPG supplier 17 4 to 25 mbar 42 5 to 57 5 mbar...

Page 16: ...e output can also be limited for DHW heating For this change coding address 6F in code 2 Checking the balanced flue system for tightness annular gap check A Combustion air port For balanced flue syste...

Page 17: ...ure of 200 Pa Removing the burner and checking the burner gasket replace gasket every 2 years 1 Switch OFF the control unit ON OFF switch and the power supply 2 Close the gas shut off valve and safegu...

Page 18: ...ally replace the burner gas ket every 2 years Checking the burner gauze assembly Replace the burner gauze assembly if the wire gauze is damaged 1 Remove electrodes A 2 Release three nuts B and remove...

Page 19: ...lectrodes for wear and contamination 2 Clean the electrodes with a small brush not with a wire brush or emery paper Please note Do not damage the wire gauze 3 Check the electrode gaps If the gaps are...

Page 20: ...s based on phosphoric acid e g Antox 75 E onto the heat exchanger A and let the solution soak in for approx 20 min 3 Thoroughly flush the heat exchanger A with water 4 Install the burner and torque nu...

Page 21: ...he diaphragm expansion vessel and reduce the pressure until the pressure gauge indicates 0 2 If the pre charge pressure of the diaphragm expansion vessel is lower than the static system pres sure top...

Page 22: ...d lower output 7 7 to 9 2 for natural gas E and LL 9 3 to 10 9 for LPG P For all gas types the O2 content must be between 4 4 and 6 9 If the actual CO2 or O2 values lie outside their respective ranges...

Page 23: ...ontent Should the actual value deviate from the above ranges by more than 1 implement steps from page 22 8 After testing press d 9 Enter actual values into the service report Matching the control unit...

Page 24: ...rature sensor 6 Heating circuit without mixer A1 Required coding Address Operation with LPG 82 1 System version 2 One heating circuit without mixer A1 and one heating circuit with mixer M2 with withou...

Page 25: ...ax temp of underfloor heating systems 8 Flow temperature sensor M2 9 Heating circuit pump M2 qP Extension kit for one heating cir cuit with mixer M2 Required coding Address Operation with LPG 82 1 Sys...

Page 26: ...g circuit without mixer A1 6 Heating circuit with mixer M2 7 Temperature limiter for limiting the max temp of underfloor heating systems 8 Flow temperature sensor M2 9 Heating circuit pump M2 qP Exten...

Page 27: ...er A1 6 Heating circuit pump A1 7 Heating circuit with mixer M2 8 Temperature limiter for limiting the max temp of underfloor heating systems 9 Flow temperature sensor M2 qP Heating circuit pump M2 qQ...

Page 28: ...with mixer M2 qP Temperature limiter for limiting the max temp of underfloor heating systems qQ Flow temperature sensor M2 qW Heating circuit pump M2 qE Extension kit for one heating cir cuit with mi...

Page 29: ...the higher the boiler water or flow temperature The room temperature again depends on the boiler water or the flow temperature Settings in the delivered condition Slope 1 4 Level 0 A Heating curve sl...

Page 30: ...et of the heating curve 1 Slope Change with coding address d3 in code 1 Setting range 2 to 35 equals slope 0 2 to 3 5 2 Level Change with coding address d4 in code 1 Setting range 13 to 40 K Further d...

Page 31: ...ith rotary selector ts The value will be automatically accepted after approx 2 s Accordingly the heating curve is adjusted along set room tempera ture axis C which results in modi fied start stop char...

Page 32: ...further functions via code 2 see the following table Note In the same LON system the same number cannot be allocated twice Only one Vitotronic may be programmed as fault manager Boiler control unit V...

Page 33: ...the following keys 1 L d simultaneously for approx 2 s Subscriber check initiated see page 33 2 e The subscriber list is updated after approx 2 min The subscriber check is completed Carrying out a su...

Page 34: ...st hand the operating instructions to the system user and instruct him her in the operation of the system Scanning and resetting the Service display The red fault indicator flashes when the limits set...

Page 35: ...n guishes Note If coding address 24 is not reset the Service message reappears On a constant temperature con trol unit After 24 hours On a weather compensated con trol unit At 07 00 h on Monday 2 Rese...

Page 36: ...d4 for the heat ing circuit without mixer A1 are scanned then the coding addresses for the heating circuit with mixer M2 are scanned Press the following keys 1 K L simultaneously for approx 2 s 2 a b...

Page 37: ...em version 2 3 4 1 heating circuit without mixer A1 and 1 mixer cir cuit M2 without DHW heating 00 6 System version 2 3 4 1 heating circuit without mixer A1 and 1 mixer cir cuit M2 with DHW heat ing M...

Page 38: ...eather compensated control units C5 1 to C5 127 Minimum limit adjustable from 1 to 127 C limited by the boiler coding card Max flow temp A1 M2 C6 74 Electronic maximum flow temperature limit 74 C only...

Page 39: ...or the required coding address the address flashes 4 d to confirm the value flashes 5 a b for the selected value 6 d to confirm the display briefly shows accepted for weather compensated control units...

Page 40: ...ing circuit without mixer A0 to Fb Heating circuit with mixer M2 A0 to Fb Note Heating systems with one heating circuit without mixer and one heating circuit with mixer Initially the possible coding a...

Page 41: ...out DHW heating 00 6 System version 2 3 4 1 heating circuit without mixer A1 1 heating cir cuit with mixer M2 with DHW heating Boiler burner 06 Maximum limit of the boiler water tempera ture defaulte...

Page 42: ...urs selected 21 1 to 21 9999 The number of hours run before the burner should be serviced is adjustable from 1 to 9999 h 23 0 No time interval for burner service selected 23 1 to 23 24 Interval adjust...

Page 43: ...0 Set speed adjustable from 0 to 100 32 0 Influence of the signal External blocking on circulation pumps All pumps in control func tion 32 1 to 32 15 Influence of the signal External blocking on circu...

Page 44: ...ner 34 0 Influence of the signal External demand on the circulation pumps All pumps in control function 34 1 to 34 23 Influence of the signal External demand on the circulation pumps see the following...

Page 45: ...OFF OFF Control funct Control funct 13 OFF OFF Control funct OFF 14 OFF OFF OFF Control funct 15 OFF OFF OFF OFF 16 ON Control funct Control funct Control funct 17 ON Control funct Control funct OFF...

Page 46: ...n sK Central fault 53 2 Function connection sK External heating circuit pump heating circuit A1 53 3 Function connection sK External circulation pump for cylinder heating 54 0 Without solar control un...

Page 47: ...ion pump without run on 62 1 to 62 15 Run on time adjustable from 1 to 15 min 63 0 Without auxiliary func tion for DHW heating only for constant tem perature control units 63 1 Auxiliary function 1 x...

Page 48: ...t ing to the second set value 73 0 DHW circulation pump ON in accordance with the time program only for weather com pensated control units 73 1 to 73 6 during the time program ON 1x h for 5 min ON up...

Page 49: ...1 A fault message is dis played providing a fault is active for at least 5 s 80 0 Immediate fault message 80 2 to 80 199 The fault message is is sued after a delay that is adjustable from 10 s to 995...

Page 50: ...128 Time constant for calcu lating the adjusted out side temperature 21 3 hours 90 0 to 90 199 Fast low values or slow high values matching of the flow temperature subject to the set value when the o...

Page 51: ...for external demand 9b 1 to 9b 127 Minimum set boiler water temperature adjustable from 1 to 127 C limited by the boiler specific parameters 9C 20 Monitoring LON sub scribers When there is no re spon...

Page 52: ...e When selecting a value below 1 C there is a risk of pipes outside the thermal envelope of the building being damaged by frost The standby mode in particular should be taken into consideration e g du...

Page 53: ...uit pump OFF if the outside tempera ture AT is 1 K higher than the set room tem perature RTset AT RTset 1 K only for weather compen sated control units A5 0 Without heating circuit pump logic function...

Page 54: ...t that takes the cooling down of an average building into considera tion A7 0 Without mixer economy function only for weath er compensated control units A7 1 With mixer economy function extended heat...

Page 55: ...hook up b0 2 Heating mode with room temperature hook up Reduced mode weather compensated b0 3 Heating mode reduced mode with room tem perature hook up b2 8 Heating with room tem perature hook up must...

Page 56: ...C5 1 to C5 127 Minimum temperature limit adjustable from 1 to 127 C limited by boiler specific parameters C6 74 Electronic maximum flow temperature limit 74 C only for weather compensated control unit...

Page 57: ...ed external heating circuit pump only for weather compensated control units E5 1 With external variable speed heating circuit pump automatic recogni tion E6 65 Maximum speed of the variable speed heat...

Page 58: ...sated control units 1 F2 0 No time limit for party mode F2 1 to F2 12 Time limit adjustable from 1 to 12 hours 1 F5 12 Run on time of the inter nal circulation pump in heating mode 12 min only for con...

Page 59: ...nsated control units F8 10 to F8 60 Temperature limit adjus table from 10 to 60 C F8 61 Function disabled F9 14 Temperature limit for raising the reduced set room temp 14 C see example on page 100 onl...

Page 60: ...weather compensated control units Fb 0 to Fb 150 Duration adjustable from 0 to 300 min 1 step 2 min Resetting codes to their delivered condition Constant temperature control unit 1 L G simultaneously...

Page 61: ...pprox 3 s 70 Fault history Press G and d simulta neously for approx 2 s Press d 71 Subscriber check in con junction with LON Press L and d simulta neously for approx 2 s Press L and d si multaneous ly...

Page 62: ...A1 Slope M2 level M2 Outside temp adj Outside temp actual The adjusted outside temperature can be reset to the actual outside temperature with e Boiler temp set Boiler temp actual DHW temp set DHW tem...

Page 63: ...n Burner control unit Type Burner control unit Equipment type 5 0 no ex ternal de mand 1 exter nal de mand 0 no ex ternal blocking 1 exter nal blocking 0 External 0 to 10 V hook up Display in C 0 no e...

Page 64: ...able speed pump Constant temperature control unit Press the following keys 1 K G simultaneously for approx 2 s 2 a b for the required scan 3 d Scanning is completed The following values can be scanne...

Page 65: ...n Burner control unit d 0 0 0 Variable speed pump 0 w o 1 Wilo 2 Grundfos Software version variable speed pump 0 no vari able speed pump Checking outputs relay test Weather compensated control unit Pr...

Page 66: ...temperature control unit Press the following keys 1 K d simultaneously for approx 2 s 2 a b for the required relay out put 3 d Relay test is completed The following relay outputs can be controlled sub...

Page 67: ...lue only for mixer circuit M2 Normal room temp C Set value Room temperature C Actual value Ext room t setpt C For external hook up DHW temp C Actual DHW temperature Solar DHW temp C Actual value Colle...

Page 68: ...3 d Scanning is completed The following operating conditions can be scanned subject to the actual system equipment level Display screen Explanation 1 15 C F Actual outside temperature 3 65 C F Actual...

Page 69: ...emperature control unit In case of a fault the fault code and fault symbol is displayed at the pro gramming unit Weather compensated control unit The display flashes Fault if a fault message is issued...

Page 70: ...ther fault codes 2 d All fault messages are acknowledged simulta neously the fault display will be deleted and the red fault indicator continues to flash Weather compensated control unit Press the fol...

Page 71: ...stem char acteristics Cause Measures 0F X X Control mode Service Service the equip ment After the service set cod ing address 24 0 10 X Regulates as if the outside temperature was 0 C Outside tem pera...

Page 72: ...blocked Boiler water temperature sensor lead broken Check the boiler water tempera ture sensor see page 83 40 X Mixer closes Heating cir cuit with mixer M2 flow tem perature sensor shorted out Check t...

Page 73: ...to the Vitosolic at S3 Check the sensor at the Vitosolic 94 X X Control mode Temperature sensor shorted out connects to the Vitosolic at S2 Check the sensor at the Vitosolic 9A X X Control mode Colle...

Page 74: ...unit service instruc tions A2 X Emergency mode with in sufficient sys tem pressure triggered by code 0d see page 41 System pressure too low Top up with water A4 X Control mode Max system pressure ex...

Page 75: ...it without mixer is con nected Internal cir culation pump blocked Check the circula tion pump b0 X X Burner blocked Flue gas temperature sensor shorted out Check the flue gas temperature sensor see pa...

Page 76: ...de without remote control Communica tion fault Vitotrol re mote control heating cir cuit A1 Check connec tions cable cod ing address A0 and remote con trol DIP switches see page 102 bd X Control mode...

Page 77: ...t external vari able speed heating cir cuit pump heating circuit A1 Check setting of coding address E5 Cd X X Control mode Communica tion fault Vitocom 100 KM BUS Check connec tions Vitocom 100 and co...

Page 78: ...gs see page 102 dE X Control mode without room influence Room tem perature sensor heat ing circuit with mixer M2 lead bro ken Check the room temperature sen sor heating cir cuit with mixer M2 and the...

Page 79: ...a fault state Heat draw off repeat edly too low during cali bration Initiate a heat draw off Switch the boiler OFF and ON again Press E RESET EC X X Burner in a fault state The ionisa tion current lie...

Page 80: ...nal is already present at burner start Check the ionisa tion electrode and connecting cable Press E RESET F4 X X Burner in a fault state No flame sig nal Check the ionisa tion electrode and cable meas...

Page 81: ...X Burner in a fault state Fan not at standstill Check the fan fan connecting cables and fan control Press E RESET FC X X Burner in a fault state Gas train faulty or faulty modu lation valve control or...

Page 82: ...er coding card or control unit if the fault persists FF X X Burner blocked or in a fault state Internal fault or E RESET key blocked Start the equip ment again Re place the control unit if the equip m...

Page 83: ...s strongly devi ate from the curve values discon nect the wires at the sensor and repeat test immediately at the sen sor 4 Subject to result replace the lead or the outside temperature sensor Checking...

Page 84: ...Check the sensor resistance and compare the actual values with the curve 3 Replace the sensor in case of severe deviation Danger The boiler water tempera ture sensor is immersed in the heating water r...

Page 85: ...with the curve 3 Replace the sensor in case of severe deviation Checking the temperature limiter Check the temperature limiter if the burner control unit cannot be reset after a fault shutdown althou...

Page 86: ...inuity of the tem perature limiter with a multimeter 3 Remove the faulty temperature lim iter 4 Install a new temperature limiter 5 After commissioning press reset button E RESET at the control unit C...

Page 87: ...tandard control mode resumes 2 Note the rotational direction of the mixer motor during its self test Then set the mixer manually to Open again Note The flow temperature sensor must now capture a highe...

Page 88: ...tch Switch position I for central heating return from the left delivered con dition Switch position II for central heat ing return from the right Checking the Vitotronic 200 H accessories The Vitotron...

Page 89: ...b a Setting values d Confirmation c Information e Standard settings Reset Heating operation The selected set boiler water tem perature will be maintained when a demand is being raised by the room ther...

Page 90: ...compensated control unit Control and display elements A Pressure gauge B Fault indicator red C Optolink interface only in conjunction with the diag nostic adaptor accessory and Vitosoft accessory D O...

Page 91: ...ure limiter inside the burner control unit limits the boiler water temperature to 82 C DHW heating The burner the circulation pump and the three way valve are started or changed over if the cylinder t...

Page 92: ...function is allocated via coding address 53 Central fault message code 53 0 Circulation pump for cylinder heat ing coding 53 3 DHW circulation pump code 53 1 delivered condition Heating circuit pump f...

Page 93: ...ss 53 Central fault message coding address 53 0 DHW circulation pump coding address 53 1 only for weather compensated operation Heating circuit pump for heating cir cuit without mixer coding address 5...

Page 94: ...rimary pump sK DHW circulation pump only for weather compensated opera tion f Power supply g Central fault message aVD External blocking terminals 2 3 External demand terminals 1 2 External heating pr...

Page 95: ...DHW circulation pump only for weather compensated opera tion f Power supply aVD External blocking terminals 2 3 External demand terminals 1 2 External heating program changeover terminals 1 2 only for...

Page 96: ...ng program changes over in cod ing address D5 Heating program changeover Coding Changeover towards Permanently reduced or Perma nent standby mode subject to the selected set value d5 0 Changeover towa...

Page 97: ...y switched ON and OFF for 30 s respec tively over a period of 20 min For a certain period the diverter valve is alternately set towards heating and DHW heating The burner is switched OFF during the ve...

Page 98: ...ched ON and the flow temperature will be held at the selected profile After completion 30 days the mixer circuit will again be regulated automatically via the set parameters Observe EN 1264 The report...

Page 99: ...profile 2 ZV parquet and flooring technology code F1 2 Temperature profile 3 Code F1 3 Temperature profile 4 Code F1 4 Temperature profile 5 Code F1 5 Control functions cont 99 Function description 5...

Page 100: ...e can be automatically raised subject to the outside tempera ture The temperature is raised in accordance with the selected heating curve but no higher than the set stan dard room temperature The outs...

Page 101: ...th reduced room temperature to operation with standard room tem perature the boiler water or flow tem perature will be raised in accordance with the selected heating curve The boiler water or flow tem...

Page 102: ...eating curve C Set boiler water or flow tempera ture in accordance with coding address FA 50 C 20 60 C D Duration of operation with raised set boiler water or flow tempera ture in accordance with codi...

Page 103: ...r rent results with air factor 1 The ionisation signal is evaluated by the combustion control unit and the air factor is adjusted to between 1 24 and 1 44 This range provides for an optimum combustion...

Page 104: ...egularly carries out an automatic self calibration also after a power failure shutdown For this the combustion is briefly regu lated to max ionisation current equals air factor 1 The automatic calibra...

Page 105: ...rature sen sor aA Ionisation electrode aG Flue gas temperature sensor d Stepper motor for diverter valve fJ Temperature limiter gF Ignition unit a Fan motor a A Fan motor control Connection and wiring...

Page 106: ...aND Water pressure sensor a Modulation coil Connection and wiring diagram internal cont 106 Designs 5692 673 GB...

Page 107: ...A1 Main PCB A2 Power supply unit Connection and wiring diagram external connections 107 Designs 5692 673 GB...

Page 108: ...low loss header Cylinder temperature sensor Plug on the cable harness s Internal circulation pump sK DHW circulation pump or External heating circuit pump or Circulation pump for cylinder heating dG G...

Page 109: ...7199 537 and 7199 538 038 Connection line for the dia phragm expansion vessel only for serial no 7199 537 and 7199 538 039 Back panel lid only for serial no 7199 537 and 7199 538 041 Plug in connector...

Page 110: ...connecting cable a 102 Gas solenoid valve connecting cable dG 103 Power cable stepper motor 104 Earth ignition module cable har ness 105 Cable harness ionisation cable KM BUS internal 202 Spray paint...

Page 111: ...Parts lists cont 111 Parts lists 5692 673 GB...

Page 112: ...Parts lists cont 112 Parts lists 5692 673 GB...

Page 113: ...Parts lists cont 113 Parts lists 5692 673 GB...

Page 114: ...Parts lists cont 114 Parts lists 5692 673 GB...

Page 115: ...bar for natural gas LL mbar 17 4 25 mbar for LPG mbar 42 5 57 5 mbar Tick gas type Carbon dioxide con tent CO2 at lower output by vol at upper output by vol Oxygen content O2 at lower output by vol at...

Page 116: ...ating kW 3 6 12 3 3 6 17 9 4 9 24 7 6 6 33 3 for DHW heating kW 3 6 16 7 3 6 17 9 4 9 24 7 6 6 33 3 Power consumption in the delivered condition W 57 61 76 78 Connection values in relation to the max...

Page 117: ...designated _ 0085 90 396 EEC 2004 108 EC 92 42 EEC 2006 95 EC This product meets the requirements of the Efficiency Directive 92 42 EEC for condensing boilers The product characteristics determined a...

Page 118: ...o duct Vitodens 300 W complies with the NOx limits specified by the 1st BImSchV paragraph 7 2 Germany Allendorf 4 September 2007 Viessmann Werke GmbH Co KG pp Manfred Sommer Manufacturer s certificate...

Page 119: ...xpansion vessel 7 Display elements 89 90 E Electronic combustion controller 103 Extension kit for heating circuit with mixer 87 Extension external H1 94 external H2 95 internal 92 internal H2 93 Exter...

Page 120: ...Rotational direction of mixer motor changing 87 checking 87 S Scanning 62 Scanning operating conditions 67 Scanning sensors 67 Screed drying 98 Screed drying function 98 Service level overview 61 Serv...

Page 121: ...121 5692 673 GB...

Page 122: ...122 5692 673 GB...

Page 123: ...123 5692 673 GB...

Page 124: ...o 35 0 kW from serial no 7199 540 7 00001 124 Printed on environmentally friendly chlorine free bleached paper 5692 673 GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendo...

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