Viessmann Vitovalor 300-P Operating instructions

Installation and service instructions

for 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.

Please follow these safety instructions closely to

prevent accidents and material losses.

Safety instructions explained

Danger

This symbol warns against the risk of injury.

!Please note

This symbol warns against the risk of material

losses and environmental pollution.

Note

Details identified by the word "Note" contain additional

information.

Target group

These instructions are exclusively intended for quali-

fied contractors.

■Work on gas installations must only be carried out by

a registered gas fitter.

■Work on electrical equipment must only be carried

out by a qualified electrician.

■The system must be commissioned by the system

installer or a qualified person authorised by the

installer.

Regulations to be observed

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for environmental protection

■Codes of practice of the relevant trade associations

■All current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE and all locally applicable

standards

aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and

ÖVE

cSEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS guideline 1942: LPG, part 2

Safety instructions for working on the system

Working on the system

■Where gas is used as the fuel, close the main gas

shut-off valve and safeguard it against unintentional

reopening.

■Isolate the system from the power supply, e.g. by

removing the separate fuse or by means of a mains

isolator, and check that it is no longer 'live'.

■Safeguard the system against reconnection.

Danger

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 components that fulfil a safety func-

tion can compromise the safe operation of the

system.

Replace faulty components only with genuine

Viessmann spare parts.

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacements, use only original spare parts

supplied or approved by Viessmann.

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explosions which may

result in serious injury.

■Do not smoke. Prevent naked flames and

sparks. Never switch lights or electrical appli-

ances on or off.

■Close the gas shut-off valve.

■Open windows and doors.

■Evacuate any people from the danger zone.

■Notify your gas or electricity supply utility from

outside the building.

■Have the power supply to the building shut off

from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to prevent flue

gases from spreading.

Safety instructions

5775 636 GB

What to do if water escapes from the appliance

Danger

When water escapes from the appliance there is

a risk of electrocution.

Switch off the heating system at the external iso-

lator (e.g. fuse box, domestic power distribu-

tion).

Flue systems and combustion air

Ensure that flue systems are clear and cannot be

sealed, for instance due to accumulation of conden-

sate or other causes. Ensure an adequate supply of

combustion air.

Instruct system users that subsequent modifications to

the building characteristics are not permissible (e.g.

cable/pipework routing, cladding or partitions).

Danger

Leaking or blocked 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 operated

at the same time, this can lead to reverse flow of the

flue gas.

Danger

The simultaneous operation of the boiler and

appliances that extract air to the outside can

result in life threatening poisoning due to

reverse flow of the flue gas.

Fit an interlock circuit or take suitable steps to

ensure an adequate supply of combustion air.

Safety instructions

Safety instructions (cont.)

5775 636 GB

1. Information Disposal of packaging ............................................................................ 7

Symbols ................................................................................................. 7

Intended use .......................................................................................... 7

Product information ................................................................................ 8

■Vitovalor 300-P, type C3TB ................................................................. 8

■Note on positioning ............................................................................. 8

2. Preparing for installation Handling ................................................................................................. 9

■Fuel cell module ................................................................................. 9

■Gas condensing module ..................................................................... 9

Siting ...................................................................................................... 9

■Dimensions of siting options ............................................................... 10

Preparing for installation ........................................................................ 11

Notes on connecting to the mains supply .............................................. 14

■Vitovalor 300-P in mains parallel mode .............................................. 14

■Metering generated power .................................................................. 14

■Property boundaries and transfer point without power storage sys-

tem ...................................................................................................... 16

■Property boundaries and transfer point with power storage system ... 17

■Connection for excess export without power storage system ............ 18

■Connection for excess export with power storage system ................. 19

■Cable sizing ........................................................................................ 20

■Fuse protection ................................................................................... 20

3. Installation sequence Installing the Vitovalor 300-P ................................................................. 22

■Removing the front panel of the gas condensing module .................. 22

■Connecting the fuel cell module on the heating water and gas 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 condensing module ................................................................ 34

■Outside temperature sensor ! (hard-wired) ..................................... 35

■External demand via switching contact .............................................. 35

■External demand via 0 – 10 V input .................................................... 36

■External blocking via switching contact .............................................. 36

■Power supply for accessories (230 V ~) ............................................. 37

■KM-BUS connections ......................................................................... 38

■Connecting Vitocom 300 to LAN ......................................................... 39

■Power supply to the system ................................................................ 39

■Installing wireless accessories (if present) ......................................... 41

■Routing the connecting cables and leads ........................................... 42

Closing the control unit enclosure .......................................................... 42

■Closing the process controller ............................................................ 43

Fitting the front panels ........................................................................... 44

If required for easier handling: Dismantling the gas condensing mod-

ule .......................................................................................................... 45

4. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 50

Index

5775 636 GB

5. Codes Coding level 1 ........................................................................................ 92

■Calling up coding level 1 ..................................................................... 92

■"General" ........................................................................................... 92

■"Boiler" .............................................................................................. 93

■"DHW" ................................................................................................ 94

■"Heating circuit ..." ........................................................................... 94

Coding level 2 ........................................................................................ 98

■Calling up coding level 2 ..................................................................... 98

■"General" ........................................................................................... 98

■"Boiler" .............................................................................................. 103

■"DHW" ................................................................................................103

■"Heating circuit ..." ........................................................................... 105

6. Diagnosis and service

scans

Gas condensing module ........................................................................ 110

■Service menu ...................................................................................... 110

■Diagnosis ............................................................................................ 111

■Checking outputs (actuator test) ......................................................... 112

Fuel cell module .....................................................................................113

■Calling up power generated ................................................................ 113

■Calling up operating condition ............................................................ 113

■Calling up grid monitoring parameters ................................................ 113

■Resetting fuel cell module data .......................................................... 114

7. Troubleshooting Fault display on gas condensing module ...............................................115

Fault codes for gas condensing module ................................................ 115

Fault display, fuel cell module ................................................................122

■Fault messages .................................................................................. 123

Repairs (gas condensing module) ......................................................... 123

■Putting the control unit into the service position ................................. 123

■Draining the 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 gas temperature sensor .........................................131

■Checking the temperature limiter ........................................................133

■Checking the fuse/MCB ......................................................................134

■Mixer extension kit ..............................................................................134

■Checking the Vitotronic 200-H (accessories) ......................................135

8. Parts lists Overview of assemblies .........................................................................137

Casing assembly ................................................................................... 138

Heat cell assembly .................................................................................140

Burner assembly ....................................................................................144

Heat cell hydraulic assembly ................................................................. 146

External connection assembly ............................................................... 148

Buffer cylinder assembly ........................................................................150

DHW cylinder assembly .........................................................................152

Miscellaneous assembly ........................................................................154

Vitovalor VBC 132 control unit assembly ...............................................156

Vitovalor VUC 170 control unit assembly .............................................. 158

Fuel cell assembly ................................................................................. 160

Index

5775 636 GB

9. Function description Control unit ............................................................................................ 164

■Heating mode ..................................................................................... 164

■Heating the DHW loading cylinder from cold ......................................164

■Operating the fuel cell module ............................................................164

■Reheating when DHW is drawn off .....................................................164

■Boosting DHW heating ....................................................................... 165

Internal H1 extension (standard delivery) .............................................. 165

Internal H2 extension (accessories) ...................................................... 166

External extensions (accessories) ......................................................... 167

■AM1 extension ....................................................................................167

■EA1 extension .................................................................................... 168

Control functions ....................................................................................169

■External operating program changeover ............................................ 169

■External blocking ................................................................................ 170

■External demand ................................................................................ 170

■Venting program ................................................................................. 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 ......................................................... 179

11. Commissioning/service

reports

................................................................................................................180

12. Specification ................................................................................................................181

13. Disposal Final decommissioning and disposal ..................................................... 182

14. Certificates Declaration of conformity ....................................................................... 183

Manufacturer's certificate according to the 1st BImSchV [Germany] .... 183

15. Keyword index ................................................................................................................184

Index

Index (cont.)

5775 636 GB

Please dispose of packaging waste in line with statu-

tory regulations.

DE: Use the disposal system organised by

Viessmann.

AT: Use the ARA statutory disposal system (Altstoff

Recycling Austria AG, licence number 5766).

CH: Packaging waste is disposed of by the HVAC

contractor.

Symbols

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion 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

Not required during maintenance

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions. It is only designed for the heating of water that is

of potable water quality and for power generation.

Intended use presupposes that a fixed installation in

conjunction with permissible, system-specific compo-

nents has been carried out.

Information

Disposal of packaging

5775 636 GB

Information

Commercial or industrial usage for a purpose other

than heating the building or DHW shall be deemed

inappropriate.

Any usage beyond this must be approved by the man-

ufacturer in each individual case.

Incorrect usage or operation of the appliance (e.g. the

appliance being opened by the system user) is prohibi-

ted and results in an exclusion of liability. Incorrect

usage also occurs if the components in the heating

system are modified from their intended use (e.g. if the

flue gas and ventilation air paths are sealed).

Product information

Vitovalor 300-P, type C3TB

Preset for operation with natural gas E, adjustable to

natural gas LL

The Vitovalor 300-P may in principle be supplied only

to the countries indicated on the type plate. For deliv-

eries to other countries, approved contractors must

arrange individual approval on their own initiative and

in accordance with the law of the country in question.

Note on positioning

When the Vitovalor 300-P 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 solar thermal system is not recommen-

ded. An integral PV system would falsify the statistical

data of the energy manager as it is not designed for

such a combination. Vitovalor 300-P runtimes could be

reduced and economically efficient operation would no

longer be guaranteed. The same applies if the

Vitovalor 300-P is operated in conjunction with a solar

thermal system or any additional heat generator. The

integral heating water buffer cylinder would be heated

additionally which would, in turn, reduce the

Vitovalor 300-P runtime. If the Vitovalor 300-P is nev-

ertheless operated in conjunction with a photovoltaic or

solar thermal system, a higher ranking energy man-

ager must be provided on site.

Information

Intended use (cont.)

5775 636 GB

Information

If possible, leave the fuel cell module and the gas con-

densing module on their pallet during handling.

Fuel cell module

■When transporting the fuel cell module, keep it upright

at all times on the pallet or its base.

■On delivery, check the tilt indicators on the packaging:

If the tilt angle on delivery is ≥ 60°, reject the delivery

but notify Viessmann.

■If possible, only remove the fuel cell module from its

pallet once it is at its final installation site. Undo the

screws and remove the transport locking plates.

Fig. 1

■Never subject the fuel cell module to strong vibrations

or shaking.

■For easier handling, the fuel cell 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.

Fig. 2

AAppliance 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, or subject it to pressure.

If space constraints make it necessary, the gas

condensing module can be split for handling.

See page 45 for an illustration of the necessary

measures.

Siting

Room height required: min. 2250 mm The Vitovalor 300-P must be installed with the gas

condensing module downstream of the fuel cell mod-

ule in the flue gas flow direction.

Preparing for installation

Handling

5775 636 GB

Installation

Dimensions of siting options

2250

1085

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

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