Viessmann VITODENS 333-F WS3A Operating instructions

VIESMANN
Service instructions
for contractors
Vitodens 333-F
Type WS3A
Compact gas fired condensing boiler
6.6 to 26 kW natural gas and LPG version
For applicability, see the last page
VITODENS 333-F
5692 731 GB 4/2007 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
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&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
Observe the following when working
on this system
&all 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 as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 731 GB

Working on the system
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static 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 parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 731 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 41
Code 2........................................................................................................ 43
Resetting codes to their delivered condition ................................................ 62
Service scans
Service level overview ................................................................................ 63
Temperatures, boiler coding card and brief scans ........................................ 64
Checking outputs (relay test) ...................................................................... 67
Scanning operating conditions and sensors ................................................ 68
Troubleshooting
Fault display ............................................................................................... 71
Fault codes................................................................................................. 73
Repairs ...................................................................................................... 82
Function description
Constant temperature control unit ............................................................... 91
Weather-compensated control unit.............................................................. 93
Extensions for external connections............................................................ 95
Control functions ........................................................................................ 99
Remote control DIP switches ...................................................................... 105
Designs
Connection and wiring diagram –internal connections ................................ 107
Connection and wiring diagram –external connections ............................... 109
Parts lists .................................................................................................. 111
Commissioning/service reports ............................................................... 118
Specification............................................................................................. 119
Certificates
Declaration of conformity ............................................................................ 120
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 121
Keyword index .......................................................................................... 122
Index
4
Index
5692 731 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler.................................................................. 8
•03. Venting the heating system............................................... 8
•04. Filling the siphon with water............................................. 9
••• 05. Checking all connections on the heating water
side and DHW side for leaks
•06. Checking the power supply connection
• • 07. Setting the time and date (if required) –only for
weather-compensated control units.............................. 9
•08. Selecting the language (if required) –only for
weather-compensated control units.............................. 10
••• 09. Pivoting down the control unit for commissioning
and maintenance work........................................................ 11
• • 10. Checking the gas type......................................................... 11
•11. Gas type conversion ............................................................ 12
••• 12. Function sequence and possible faults ....................... 13
••• 13. Checking the static and supply pressure .................... 14
•14. Setting the maximum output ............................................ 16
•15. Checking the balanced flue system soundness
(annular gap check) ............................................................. 17
• • 16. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 18
• • 17. Checking the burner gauze assembly........................... 19
• • 18. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 20
• • 19. Cleaning the combustion chamber/heating
surfaces and fitting the burner ........................................ 21
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 731 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Checking the condensate drain and cleaning the
siphon........................................................................................ 22
• • 21. Checking the neutralising system (if installed)
•22. Testing the anode earth current with an anode
tester.......................................................................................... 22
•23. Cleaning the DHW cylinder ............................................... 23
•24. Checking and replacing the magnesium anode (if
required)................................................................................... 23
•25. Returning the DHW cylinder into use ............................ 24
• • 26. Checking the diaphragm expansion vessel and
system pressure.................................................................... 24
••• 27. Checking the function of all safety valves
••• 28. Checking the tightness of electrical connections
••• 29. Checking all gas equipment for soundness at
operating pressure............................................................... 25
••• 30. Flue gas emissions test...................................................... 25
••• 31. Checking the ionisation current ..................................... 27
••• 32. Checking the external LPG safety valve (if
installed)
•33. Matching the control unit to the heating system ...... 28
•34. Adjusting the heating curves (only for weather-
compensated control units).............................................. 33
•35. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 36
•36. Instructing the system user .............................................. 38
•37. Scanning and resetting the "Service" display ........... 38
••• 38. Locking the control unit and fitting the front
panels........................................................................................ 40
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 731 GB

Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water with hardness exceeding 3.0 mmol/l e.g. use a small
softening system for heating water (see Vitoset price list).
&An antifreeze additive suitable for heating systems can be mixed with
the fill water.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system at the fill
valve in the heating return (on the
connection set or on site).
(Minimum system pressure
> 0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its cen-
tral position, and the system will be
completely filled.
4. If the control unit was already
switched ON before filling began:
Switch ON the control unit and acti-
vate the filling program via code
"2F:2".
Note
To call up coding level 1 and for
setting the coding address, see
page 41.
For function and details of the fill
program, see page 100.
Whilst the fill program is running,
the display shows "bF"
(Vitotronic 100) or "Befüllung"
(filling) (Vitotronic 200).
5. Close the boiler fill & drain valve.
6. Set code "2F:0".
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 731 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose on valve
Awith a drain.
3. Open valve Aand filling valve in
the heating return and vent using
mains pressure until no more air
noise can be heard.
4. Close valve Aand the fill valve in
the heating return and open the
shut-off valves on the heating
water side.
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit.
2. Activate the venting program via
code "2F:1".
Note
To call up coding level 1 and for
setting the coding address, see
page 41.
For function and sequence of the
venting program, see page 100.
Whilst the venting program is run-
ning, the display shows "EL"
(Vitotronic 100) or "Entlüftung"
(venting) (Vitotronic 200).
3. Check the system pressure.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 731 GB

Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fill the siphon with water.
3. Fit siphon Aand secure with the
retaining clip.
Setting the time and date (if required) –only for weather-
compensated control units
Note
&During commissioning, or after a
prolonged time out of use, it may be
necessary to reset the time and
date, if the time flashes in the dis-
play.
&During commissioning these terms
appear in German (delivered condi-
tion):
Time (see step 1)
Date (see step 2)
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" (date)
is displayed.
3. a/bfor the current date.
4. dto confirm.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 731 GB

Selecting the language (if required) –only for weather-com-
pensated control units
Note
When the unit is first taken into opera-
tion the display is in German (default
language setting):
Select heating circuit (see step 1.)
Outside temperature (see step 3.)
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
3. cpress this button again,
"Außentemperatur" (outside
temperature) is displayed.
4. bfor the required language.
5. dto confirm.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 731 GB

Pivoting down the control unit for commissioning and main-
tenance work
1. Undo two screws and push panel
Aup and to the left.
2. Open flap B.
3. Release side closures Cand pivot
control unit Dforward.
4. Release the side screws and pivot
control unit Ddown with its retain-
ing frame E.
Checking the gas type
Note
In the delivered condition, the Vitodens 333-F is set up for natural gas E.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 731 GB

1. Check the gas type and Wobbe
index (Wo) with your mains gas or
LPG supplier and compare them
with the details on the burner label.
2. If these details do not match, con-
vert the burner to the available gas
type.
Conversion kit installation
instructions.
3. Adjust the gas type via coding
address "1E" at the control unit.
Note
To call up code 1 and for setting the
coding address, see page 41.
4. Record the gas type in the service
report on page 118.
Wobbe index ranges
Gas type Wobbe index range
kWh/m
3
MJ/m
3
Delivered condition
Natural gas E 12.0 to 16.1 43.2 to 58.0
After conversion
Natural gas LL 10.0 to 13.1 36.0 to 47.2
LPG P 20.3 to 21.3 72.9 to 76.8
Gas type conversion
Gas restrictor installation
instructions
Gas restrictor allocation
Rated output kW 26
Internal 7gas restrictor
Gas
&Natural gas E mm 5.95
&Natural gas LL mm 6.73
&LPG P mm 4.4
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 731 GB

Function sequence and possible faults
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Yes
Fan starts No After approx. 51 s
fault F5/F9
Check fan cables
and plug-in con-
nectors
Yes
Differential pres-
sure sensor en-
ables start
(0.75 V across
terminals "X8.5"
and "X8.6")
No After approx. 51 s
fault E6/F5
Check fan cables
and plug-in con-
nectors, check
fan
Yes
Ignition No Fault F4 Check ignition
module (control
voltage 230 V
across plugs
"X2.1" and
"X2.2")
Yes
Gas train opens No Fault F4 Check the gas
train (control vol-
tage 230 V);
check the gas
supply pressure
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 731 GB

Yes
Ionisation cur-
rent builds
(higher than
2 µA)
Symbol A
No Fault F4 Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks.
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 the gas
flow pressure
For further details regarding faults, see page 71.
Checking the static and supply pressure
Danger
CO build-up as a result of an incorrect burner setup can have serious
health implications.
Carry out a CO test prior to and after work on gas equipment.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas supply lines after flushing.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 731 GB

1. Close the gas shut-off valve.
2. Release screw Ainside test con-
nector "PE" on the gas train, but do
not remove it; then connect the
pressure gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 118.
Set value: max. 57.5 mbar
5. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 s press "E" to reset the
burner.
6. Check the supply (flow) pressure.
Set value:
&Natural gas: 20 mbar
&LPG: 37/50 mbar
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
7. Record the actual value in the ser-
vice report on page 118.
Take the action shown in the follow-
ing table.
8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test port Awith
the screw.
9. Open the gas shut-off valve and
start up the boiler.
Danger
Gas escaping from the test
port leads to a risk of explo-
sion.
Check test connector Afor
soundness.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 731 GB

Supply (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 25 to 57.5 mbar Start the boiler.
above 25 mbar above 57.5 mbar Install a separate gas pressure gover-
nor upstream of the system and regu-
late the inlet pressure to 20 mbar for
natural gas or 50 mbar for LPG. Notify
your mains gas or LPG supplier.
Setting the maximum output
Note
You can limit the maximum output for heating operation. The limit is set via the
modulation range.
1. Start the boiler.
2. K+Fpress simultaneously:
"100" flashes (equals
100% of rated output)
and "A" is displayed.
On weather-compen-
sated control units, the
display additionally
shows "Max.heating
output".
a/bpress for the required
value in % of rated output
as max. output.
dto confirm.
3. Record the setting for the maxi-
mum output on the additional type
plate supplied with the "technical
documentation". Affix the type
plate next to the type plate on top
of the boiler.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 731 GB

Checking the balanced flue system soundness (annular gap
check)
ACombustion air port (ventilation
air)
For balanced flue systems tested
together with the wall mounted gas
fired boiler, some authorities waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
We recommend that your heating
engineer carries out a simple sound-
ness test during the commissioning of
your system. For this, it would be suf-
ficient to check the CO2or O2concen-
tration in the combustion air at the
annular gap of the balanced flue pipe.
The flue pipe is deemed to be sound if
the CO2concentration in the combus-
tion air is no higher than 0.2 % or the
O2concentration is at least 20.6 %.
If actual CO2values are higher or O2
values are lower, then pressure test
the flue pipe with a static pressure of
200 Pa.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 731 GB

Removing the burner and checking the burner gasket
(replace gasket every two years)
1. Switch OFF the mains power sup-
ply to the control unit at the ON/
OFF switch.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull electrical cables from differen-
tial pressure sensor A, gas valve
B, ionisation electrode C, earth
tab D, fan motor Eand ignition
unit F.
4. Undo the fixing screws of gas con-
nection flange G.
5. Release four nuts Hand remove
the burner.
!Please note
Prevent damage to the wire
gauze.
Never rest the burner on the
gauze assembly.
6. Check burner gasket Kfor
damage.
Generally replace the burner gas-
ket every 2 years.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 731 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if
the wire gauze is damaged.
1. Remove electrodes A.
2. Release six Torx screws Band
remove burner gauze assembly
C.
3. Remove old burner gauze assem-
bly gasket D.
4. Insert a new burner gauze assem-
bly with a new gasket and secure
with six Torx screws.
Note
Torque: 3.5 Nm
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 731 GB

Checking and adjusting the ignition and ionisation electro-
des
AIgnition electrodes BIonisation electrode
CGasket
1. Check the electrodes 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 not as specified or the
electrodes are damaged, replace
and align the electrodes together
with new gaskets. Tighten the elec-
trode fixing screws with 2 Nm.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 731 GB