Viessmann VITODENS 333 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 333
Type WS3B
Compact gas fired condensing boiler
4.2 to 19 kW natural gas and LPG version
For applicability, see the last page
VITODENS 333
5692 568 GB 12/2005 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 568 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 mains isola-
tor.
&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 568 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 6
Further details regarding the individual steps .............................................. 9
Coding
Code 1........................................................................................................ 42
Code 2........................................................................................................ 44
Resetting codes to the delivered condition .................................................. 61
Service scans
Service level overview ................................................................................ 62
Temperatures, boiler coding card and brief scans ....................................... 63
Checking outputs (relay test) ...................................................................... 66
Scanning operating conditions and sensors ................................................ 67
Troubleshooting
Fault display ............................................................................................... 70
Calling up fault codes from the fault memory (fault history) .......................... 71
Fault codes................................................................................................. 72
Repairs ...................................................................................................... 80
Function description
Constant temperature control unit ............................................................... 90
Weather–compensated control unit............................................................. 92
Extensions for external connections............................................................ 95
Control functions ........................................................................................ 99
Remote control DIP switches ...................................................................... 105
Electronic combustion control unit............................................................... 105
Designs
Connection and wiring diagram –internal connections ................................ 107
Connection and wiring diagrams –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
Index
4
Index
5692 568 GB

Keyword index .......................................................................................... 122
Index (cont.)
5
Index
5692 568 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 9
•02. Venting the boiler .................................................................. 10
•03. Venting the heating system............................................... 10
•04. Filling the siphon with water............................................. 11
••• 05. Checking all connections on the primary 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.............................. 11
•08. Selecting the language (if required) ‐only for
weather‐compensated control units.............................. 11
••• 09. Pivoting down the control unit for commissioning
and maintenance work........................................................ 12
• • 10. Checking the gas type......................................................... 12
•11. Gas type conversion (only for operation with LPG) .13
••• 12. Function sequence and possible faults ....................... 14
••• 13. Checking the static and supply pressure .................... 15
•14. Setting the maximum output ............................................ 17
•15. Checking the balanced flue system soundness
(annular gap check) ............................................................. 18
• • 16. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 19
• • 17. Checking the burner gauze assembly........................... 20
• • 18. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 21
• • 19. Cleaning the combustion chamber/heating
surfaces and fitting the burner ........................................ 22
Steps –initial start-up, inspection and maintenance
6
Initial start-up, inspection, maintenance
5692 568 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Checking the condensate drain and cleaning the
siphon........................................................................................ 23
• • 21. Checking the neutralising system (if installed)
•22. Testing the anode earth current with an anode
tester.......................................................................................... 23
•23. Cleaning the DHW cylinder ............................................... 24
•24. Checking and replacing the magnesium anode (if
required)................................................................................... 24
•25. Returning the DHW cylinder into use ............................ 25
••• 26. Checking the diaphragm expansion vessel and
system pressure
••• 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. Checking the combustion quality................................... 26
••• 31. Checking the ionisation current...................................... 28
••• 32. Checking the external LPG safety valve (if
installed)
•33. Matching the control unit to the heating system ...... 28
•34. Adjusting the heating curve (only for weather‐
compensated control units).............................................. 34
•35. Connecting the control unit to the LON system
(only for weather‐compensated control units) .......... 37
•36. Implementing a user check (in conjunction with
the LON system for weather‐compensated control
units).......................................................................................... 39
•37. Instructing the system user .............................................. 39
•38. Scanning and resetting the "Maintenance" display 40
Steps –initial start-up, inspection and . . . (cont.)
7
Initial start-up, inspection, maintenance
5692 568 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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••• 39. Locking the control unit and fitting the front
panels........................................................................................ 41
Steps –initial start-up, inspection and . . . (cont.)
8
Initial start-up, inspection, maintenance
5692 568 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.
&Fill water with a water hardness in excess of 3.58 mmol/l must be sof-
tened, e.g. with the small softening system for heating water (see the
Vitoset pricelist).
&An anti‐freeze 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 servo drive of the
changeover valve will still be in its
central position, and the system
will be completely filled.
4. If the control unit had already been
switched ON before filling began:
Start the control unit and activate
the fill program via coding "2F:2".
Note
To call up coding level 1 and for
setting the coding address, see
page 42.
For function and details of the fill
program, see page 100.
Whilst the fill program runs, the dis-
play shows "bF" (Vitotronic 100) or
"Filling" (Vitotronic 200).
5. Close the boiler fill & drain valve.
6. Set code "2F:0".
Further details regarding the individual steps
9
Initial start-up, inspection, maintenance
5692 568 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 outlet.
3. Open valve Aand the fill valve in
the heating return and vent at
mains pressure, until no sound of
escaping air can be heard any-
more.
4. Close valve Aand the fill valve in
the heating return and open the pri-
mary shut‐off valves.
Venting the heating system
1. Close the gas shut‐off valve and
switch ON the control unit.
2. Activate the venting program via
coding "2F:1".
Note
To call up coding level 1 and for
setting the coding address, see
page 42.
For function and sequence of the
venting program, see page 100.
Whilst the venting program runs,
the display shows "EL"
(Vitotronic 100) or "Venting"
(Vitotronic 200).
3. Check the system pressure.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 568 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 prolonged time out of use, it may be necessary
to set the time and date, if the time flashes in the display.
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Date" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Selecting the language (if required) ‐only for weather‐com-
pensated control units
Press the following keys:
1. c"Select a heating circuit" will
be displayed.
2. dto confirm; wait approx. 4 s.
3. cpress again.
4. bfor the required language.
5. dto confirm.
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 568 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 the 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
The boiler is equipped with an electronic combustion control unit, which adjusts
the burner for optimum combustion in accordance with the prevailing gas qual-
ity.
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 568 GB

&For natural gas, there is consequently no adjustment required across the
entire Wobbe range.
&The boiler can be operated in the Wobbe index range 10.0 to 16.1 kWh/m
3
(36.0 to 58.0 MJ/m
3
).
&Adjust the burner for operation with LPG (see "Changing the gas type" on
page 13).
1. Determine the gas type and Wobbe
index (Wo) by asking your local
mains gas or LPG supplier.
2. Convert the burner for operation
with LPG (see page 13).
3. Record the gas type in the service
report on page 118.
Gas type conversion (only for operation with LPG)
1. Turn adjusting screw A(Allen
screw 2.5 mm) on the gas combina-
tion valve clockwise as far as possi-
ble towards "–" (approx. 30 turns).
2. Switch ON the system ON/OFF
switch "8".
3. Adjust the gas type in coding
address "82" (for a detailed
description of the individual steps,
see page 88):
&Call up code 2
&In coding address "11", select
value "9"
&In coding address "82", select
value "1" (operation with LPG)
&Set code "11" ≠"9"
&Terminate coding 2.
4. Open the gas shut‐off valve.
5. Affix label "G31" (included with the
technical documentation) above
label "G20/G25" on the cap panel.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 568 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 Check fan cables
and plugs
Fault F9
Yes
Ignition No Fault F4 Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and
"X2.2")
Yes
Gas combination
valve opens No Fault F4 Check the gas
combination valve
(control voltage
230 V); check the
gas supply pres-
sure
Yes
Ionisation cur-
rent builds
(higher than
5 µA) No
Fault F4 Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks.
Symbol A
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 568 GB

Yes
Burner in opera-
tion
Stops below set
boiler water tem-
perature and re-
starts
Check flue gas
system for sound-
ness (flue gas re-
circulation),
check gas flow
pressure
Yes
Automatic cali-
bration of the
combustion con-
trol unit
No Fault Eb Check the electri-
cal connecting
cable and the io-
nisation electrode
For further details regarding faults, see page 70.
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 lines after flushing.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 568 GB

1. Close the gas shut‐off valve.
2. Release screw Ainside test nipple
"PE" on the gas combination valve,
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 values:
&Natural gas 20 mbar
&LPG 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.
Take the action shown in the table.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 568 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 57.5 mbar 42.5 to
57.5 mbar
Start the boiler.
in excess of
57.5 mbar
in excess of
57.5 mbar
Install a separate gas governor up-
stream of the system. Regulate the pres-
sure to 20 mbar for natural gas or
50 mbar for LPG. Notify your mains gas
or LPG supplier.
8. Shut down the boiler, close the gas
shut‐off valve, remove the pressure
gauge and close test port Awith
the screw.
9. Danger
Gas escaping from the test
port leads to a risk of explo-
sion.
Check for soundness.
Open the gas shut‐off valve, start
the boiler and check the soundness
of test port A.
Setting the maximum output
The maximum output can be limited for heating operation. You can limit the
output via the modulation range.
1. Start the boiler.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 568 GB

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. output".
a/bpress for the required
value in % of rated output
as max. output.
dto confirm.
3. Record the setting for max. output
on the additional type plate sup-
plied with the "technical documen-
tation". Affix the type plate next to
the type plate on top of the boiler.
Checking the balanced flue system soundness (annular gap
check)
For balanced flue systems tested together with the wall mounted gas fired boil-
er, some authorities waive the requirement for a soundness test (overpressure
test) during commissioning by the flue gas inspector.
We recommend that your heating engineer carries out a simple leak test during
the commissioning of your system. For this it would be sufficient to check the
CO2concentration in the combustion air at the annular gap of the balanced flue
pipe.
ACombustion air port (ventilation
air)
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.)
18
Initial start-up, inspection, maintenance
5692 568 GB

Removing the burner and checking the burner gasket
(replace gasket every two years)
1. Switch OFF the control unit ON/
OFF switch and the power supply.
2. Close the gas shut‐off valve and
safeguard against reopening.
3. Pull electrical cables from fan
motor A, gas valve B, ionisation
electrode C, ignition unit Dand
earth tab E.
4. Undo the fixing screws of gas sup-
ply flange F.
5. Release four nuts Gand remove
the burner.
!Please note
Prevent damage to the wire
gauze.
Never rest the burner on the
gauze assembly.
6. Check burner gasket Hfor
damage.
Generally replace the burner gas-
ket every 2 years.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 568 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if
the wire gauze is damaged.
1. Remove electrodes A.
2. Release three nuts Band remove
burner gauze assembly C.
3. Remove old burner gauze gasket
D.
4. Insert a new burner gauze assem-
bly with a new gasket and secure
with three nuts.
Note
Torque: 4 Nm
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 568 GB