Viessmann VITODENS 333 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 333
Type WS3A, 4.2 to 13.0 kW
Compact gas fired condensing boiler
natural gas and LPG version
See applicability on the last page
VITODENS 333
5692 579 GB 11/2004 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.
!Important information
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the words "Note"
contain additional information.
Warranty
All warranty rights are void if these
service instructions are not observed.
Target group
These service instructions are exclu-
sively designed for qualified person-
nel.
Work on gas equipment must only be
carried out by a registered gas fitter.
Only approved contractors may mod-
ify this equipment for countries other
than those designated on the type
plate. That contractor will then
arrange for the relevant approval in
that country.
Electrical work must only be carried
out by a qualified electrician.
The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following during service
work:
&all legal instructions regarding the
prevention of accidents,
&the TRGI, TRF and special regula-
tions, e.g. those of the BDH,
&all legal instructions regarding
environmental protection,
&the Code of Practice by relevant
trade associations and all local reg-
ulations.
If you notice a smell of gas
Danger
Escaping gas can cause explo-
sionswhichmayleadtoser-
ious injury.
&Do not smoke. Prevent
naked flames and sparks.
Never switch electrical lights
or equipment.
&Open windows and doors.
&Close the gas shut-off valve.
&Remove all personnel from
the danger zone.
&Observe the safety regula-
tions of your local gas sup-
plier which can be found on
the gas meter.
&Notify your heating contrac-
tor from outside the building.
Safety instructions
2
Safety instructions
5692 579 GB

If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Repair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Service work on the heating system
&Isolate the system from mains sup-
ply, e.g. by removing a separate
fuse or by means of a mains electri-
cal isolator, and check that it is no
longer 'live'.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
Ancillary components, spare and
wearing parts
!Important information
Components which are not
tested with the heating system,
the installation of non-
approved spare parts and
unauthorised conversion may
lead to damage to the heating
system, which may affect their
function and limit our warranty.
For conversions or replace-
ments, use only original parts
from Viessmann or those spare
parts which are approved by
Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 579 GB

Initial start-up, inspection, maintenance
Steps - initial start-up, inspection and maintenance ..................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 39
Code 2........................................................................................................ 42
Resetting coding to as delivered condition .................................................. 61
Service scans
Service level summary................................................................................ 62
Temperatures, boiler coding card and brief scans ....................................... 63
Checking outputs (relay test) ...................................................................... 67
Scanning operating conditions and sensors ................................................ 69
Troubleshooting
Downloading fault codes history.................................................................. 72
Calling up current fault codes...................................................................... 72
Checking and acknowledging faults ........................................................... 74
Repairs ...................................................................................................... 83
Function description
Constant temperature control unit ............................................................... 94
Weather-compensated control unit.............................................................. 96
Internal extension H1.................................................................................. 98
Extensions for external connections (accessories) ...................................... 99
Control functions ........................................................................................ 102
Designs
Connection and wiring diagrams –internal connections .............................. 107
Connection and wiring diagrams –external connections.............................. 109
Parts lists .................................................................................................. 111
Commissioning/service reports............................................................... 118
Specification............................................................................................. 124
Certificates
Declaration of conformity ............................................................................ 125
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 126
Keyword index .......................................................................................... 127
Index
4
Index
5692 579 GB

For further instructions on individual steps, see pages indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•1. Filling the heating system ................................................. 7
•2. Venting the boiler.................................................................. 8
•3. Venting the heating system............................................... 8
•4. Filling the siphon with water............................................. 9
•5. Checking the electrical mains connection
•6. Language selection (if required) –only for the
weather-compensated control units ............................. 9
•• 7. Setting the time and date (if required) –only for
weather-compensated control units ............................. 9
••• 8. Pivoting the control unit down to carry out
commissioning and maintenance work........................ 10
••9. Checking the gas type......................................................... 11
•10. Gas type conversion............................................................ 11
••• 11. Function sequence and possible faults........................ 12
•12. Changing the gas type (see separate installation
instructions)
••• 13. Checking static and supply pressure ........................... 13
••• 14. Checking the CO2settings ................................................ 15
•15. Setting the max. output ...................................................... 17
••• 16. Checking all connections on the primary and DHW
side for leaks
••• 17. Checking the burner (recording values on
page 118 of commissioning report)
•18. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 18
•• 19. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 19
•• 20. Checking the burner gauze assembly........................... 20
Steps - initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 579 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 21. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 21
•• 22. Cleaning the combustion chamber/heating
surfaces and installing the burner ................................. 22
•• 23. Checking the condensate drain and cleaning the
siphon........................................................................................ 23
•• 24. Checking the neutralising system (if installed)
•25. Testing anode earth current with an anode tester.... 23
•26. Cleaning the DHW cylinder ............................................... 24
•27. Checking and replacing the magnesium anode (if
required)................................................................................... 25
•28. Taking the DHW cylinder back into use ........................ 25
••• 29. Checking the diaphragm expansion vessel and
system pressure
••• 30. Checking the function of all safety valves
••• 31. Checking tightness of electrical connections
••• 32. Checking all gas equipment for soundness at
operating pressure .............................................................. 26
••• 33. Checking the ionisation current ..................................... 26
••• 34. Checking the external LPG safety valve (if
installed)
•35. Matching the control unit to the heating system ...... 27
•36. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 32
•37. Implementing a user check (in conjunction with
the LON system) .................................................................... 33
•38. Adjusting heating curves (only for weather-
compensated control units).............................................. 34
•39. Instructing the system user .............................................. 38
•40. Scanning and resetting the "Maintenance" display 38
Steps - initial start-up, inspection and . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 579 GB

Filling the heating system
!Important information
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 with water.
&Only use fill water of potable quality.
&Softenfillwaterharderthan20°dH(3.58mmol/l).
&An anti-freeze additive suitable for heating systems can be mixed with
the fill water.
1. Check the charge pressure of the
diaphragm 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). (min.
system pressure > 0.8 bar).
Note
&If the control unit had not already
been switched ON before filling
began: The diverter valve is in
centre position, and the system
will be completely filled.
&If the control unit had already
been switched ON before filling
began: In code 1, set coding
address 2F:2 (see page 39).
The diverter valve will then be in
its central position.
Whilst filling is in progress, the
display shows bF (constant tem-
perature control unit) or "Filling"
(weather-compensated control
unit).
4. Close the boiler fill & drain valve.
5. Set coding address 2F:0.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 579 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose on valve A
with a drain outlet.
3. Open valve Aandfillvalveinthe
heating return, and vent at mains
pressure, until no sound of escap-
ingaircanbeheardanymore.
4. Close valve Aand 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
start the control unit.
2. Activate the venting program via
coding address 2F:1.
Note
To call up code 1 and for setting the
coding address, see page 39.
For function and sequence of the
venting program, see page 103.
Whilst venting is in progress, the
display shows "EL" (constant tem-
perature control unit) or "Venting"
(weather-compensated control
unit).
3. Check the system pressure.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 579 GB

Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fillthesiphonwithwater.
3. Fit siphon Aandsecurewiththe
retaining clip.
Language selection (if required) –only for the weather-com-
pensated control units
1. Press c.
The display shows "Heizkreis aus-
wählen".
2. Press d.
3. After approx. 4 seconds press c.
4. Select the required language
with b.
5. Confirm with d.
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.
1. Set the correct time with a/b.
2. Confirm with d.
3. Set the current date with a/b.
4. Confirm with d.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 579 GB

Pivoting the control unit down to carry out commissioning
and maintenance work
1. Open flap A.
2. Release side closures Band pivot
control unit Cforward.
3. Release the side screws and pivot
control unit Cdown with its retain-
ing frame D.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 579 GB

Checking the gas type
1. Enquire about the gas type and
Wobbe index (Wo) from your local
mains gas or LPG supplier.
Note
In its delivered condition, Vito-
dens 333 is set up for natural gas
E.
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m
3
(43.2to58.0MJ/m
3
).
2. Compare the gas category (gas
type) and gas group with the details
on the burner label.
3. If these details do not match the
fuel provided, the burner must be
convertedaccordingtothedetails
provided by the mains gas or the
LPG supplier.
Conversion kit installation
instructions.
After conversion to
&Natural gas LL
The boiler can be operated in the
Wobbe index range 10.0 to
13.1 kWh/m
3
(36.0to47.2MJ/
m
3
).
&LPG P
The boiler can be operated in the
Wobbe index range 21.4 to
22.5 kWh/m
3
(76.9to81.0MJ/
m
3
).
4. Set 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 39.
5. Record the gas type in the service
report on page 118.
Gas type conversion
Gas restrictor installation
instructions
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 579 GB

Gas restrictor allocation
Gas type Internal 7
gas restric-
tor
&Natural
gas E
mm 4.8
&Natural
gas LL
mm 5.3
&LPG P mm 3.7
Function sequence and possible faults
For further details regarding faults, see page 74.
Display screen Remedy
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
F5/F9
Yes
Differential pres-
sure sensor en-
ables start (0.75
Vacrossterm-
inals X8.5 and
X8.6)
No after approx. 51 s Check fan cables
and fan plug-in
connections,
check fan
Fault
E6/F5
Yes
Ignition No Fault Check ignition
module (control
voltage 230 V)
across terminals
X2.1 and X2.2
F4
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 579 GB

Yes
Gas combination
valve opens No Fault Check the gas
train (control vol-
tage 230 V) and
gassupplypres-
sure
F4
Yes
Ionisation cur-
rent builds
(higher than
2µA) No
Fault Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks.
Symbol AF4
Yes
Operational bur-
ner
Stops below set
boiler tempera-
ture and restarts
Check flue gas
system for sound-
ness (flue gas re-
circulation),
check gas flow
pressure
Checking static and supply pressure
Danger
Higher CO emissions can lead to poisoning.
Measure the CO value before and after any work on gas equipment to
prevent any health hazards and to ensure the perfect operational condi-
tion of the system.
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.)
13
Initial start-up, inspection, maintenance
5692 579 GB

1. Close the gas shut-off valve.
2. Release the screw inside test nip-
ple PE Aon the gas combination
valve, but do not remove, and con-
nect the pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure; it should
be a max. of 57.5 mbar. Record the
actual value in the service report.
5. Start up boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 seconds, press Eto
reset the burner.
6. Check the supply (flow) pressure; it
should be
&20 mbar for natural gas,
&and 50 mbar for LPG.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
Record the actual value in the ser-
vice report.
Taketheactionshowninthetable.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 579 GB

Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Remedy
below 17.4 mbar below 42.5 mbar Do not start up. Notify your mains gas or
LPG supplier.
17.4 to 57.5 mbar 42.5 to 57.5
mbar
Start up boiler.
in excess of
57.5 mbar
in excess of
57.5 mbar
Install a separate gas governor down-
stream of the system and regulate the
pressure to 20 mbar for natural gas or
50 mbar for LPG. Notify your mains gas
or LPG supplier.
7. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge, and close test nipple A
with the screw.
8. Open the gas shut-off valve and
start the boiler.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check test nipple Afor
soundness.
Checking the CO2settings
Vitodens 333 is set up in the factory for natural gas E, and can be converted to
natural gas LL or LPG P using a conversion kit.
During commissioning or maintenance, check the CO2level at the boiler adap-
tor.
Note
The MatriX burner for Vitodens 333 is preset for the entire gas group. Therefore,
the burner requires no further setting or adjustment.
Subject to the Wobbe index, the CO2content fluctuates between
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 579 GB

&6.6 to 10.0 % for natural gas E
&7.0 to 10.0 % for natural gas LL and
&8.5to10.5%forLPGP.
Compare the actual CO2value with the above CO2value ranges for the indivi-
dual gas groups (check the gas group with your mains gas or LPG supplier).
If the actual CO2value deviates by more than 1 % for natural gas or 0.5 % for
LPG, proceed as follows:
&Check whether the correct gas restrictor has been installed.
&Check the balanced flue system for soundness, see page 18.
1. Connect a flue gas analyser at flue
gas aperture Aon the boiler adap-
tor.
2. Open the gas shut-off valve, com-
mission the boiler and create a heat
demand.
3. Select the lower rated output.
Constant temperature control unit:
&Press both keys 9and dsimul-
taneously, until the display shows
1.
Weather-compensated control unit:
&Press both keys 9and dsimul-
taneously until the display shows
"Relay test".
&With a/bin the display, select
"Basic load".
4. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 15.
5. Enter actual values into the service
report.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 579 GB

6. Set the upper rated output.
Constant temperature control unit:
&With a/bin the display, select
2.
Weather-compensated control unit:
&With a/bin the display, select
"Full load".
7. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 15.
8. After testing, press d.
9. Enter actual values into the service
report.
Setting the max. output
Note
The max. output can be limited for heating operation. You can limit the output
via the modulation range.
1. Start up boiler.
2. Press both Kand Fsimulta-
neously until 100 flashes on the
display, (equals 100 % of the rated
output) and Aappears. On
weather-compensated control
units, the display additionally
shows "Max. output".
3. With a/bselect the required
value in % of rated output as max.
output.
4. Confirm the set value with d.
5. Record the settings for max. output
on the additional type plate
included with the technical docu-
mentation. Affix the type plate next
to the original type plate on top of
the boiler.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 579 GB

Checking the balanced flue system for soundness (annular
gap check)
ACombustion air aperture
For balanced flue systems tested
together with the gas fired wall
mounted boiler, some Federal States
(e.g. Northrhein-Westphalia) waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
For such cases we recommend that
your heating contractor carries out a
simple soundness test during the
initial start-up of your system. For
this, it would be sufficient to check the
CO2concentration in the combustion
air at the annular gap in the balanced
flue pipe.
Thefluepipeisdeemedtobesoundif
the CO2concentration of 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, check flue pipe for
leaks at a static pressure of 200 Pa.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 579 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 mains electri-
cal supply.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull electrical cables off fan motor
A, differential pressure sensor
B,gasvalveC, ionisation elec-
trode D, ignition unit Eand earth
F.
4. Release gas connection pipe G
fixing screws and fittings.
5. Release four nuts Hand remove
the burner.
!Important information
Prevent damage to the wire
mesh.
Never rest the burner on the
gauze assembly.
6. Check burner gasket Kfor
damage.
Generally, replace the burner gas-
ket every two years.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 579 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if
the wire mesh is damaged.
1. Remove electrodes A.
2. Release six Torx screws Band
remove burner gauze assembly
C.
3. Remove old gauze assembly gas-
ket 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.)
20
Initial start-up, inspection, maintenance
5692 579 GB