Viessmann VITODENS 333 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 333
Type WS3A
Compact gas fired condensing boiler
4.2 to 13 kW natural gas version
6.6 to 26 kW natural gas and LPG version
For applicability, see the last page
VITODENS 333
5692 619 GB 8/2005 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,
&theCodeofPracticeofrelevant
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.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 619 GB

Workingonthesystem
&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 619 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........................................................................................................ 41
Resetting codes to the delivered condition .................................................. 60
Service scans
Service level summary................................................................................ 61
Temperatures, boiler coding card and brief scans ....................................... 62
Checking outputs (relay test) ...................................................................... 65
Scanning operating conditions and sensors ................................................ 67
Troubleshooting
Fault display ............................................................................................... 69
Calling up fault codes from the fault memory (fault history) .......................... 71
Fault codes................................................................................................. 71
Repairs ...................................................................................................... 79
Function description
Constant temperature control unit ............................................................... 90
Weather–compensated control unit ............................................................. 92
Extensions for external connections............................................................ 95
Control functions ........................................................................................ 99
Remote control DIP switch .......................................................................... 105
Designs
Connection and wiring diagram –internal connections ................................ 106
Connection and wiring diagram –external connections ............................... 108
Parts lists .................................................................................................. 110
Commissioning/service reports............................................................... 117
Specification............................................................................................. 118
Certificates
Declaration of conformity ............................................................................ 119
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 120
Keyword index .......................................................................................... 121
Index
4
Index
5692 619 GB

For further information regarding individual steps, see the 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 all connections on the primary and DHW
side for leaks
•6. Checking the power supply connection
•• 7. Setting the time and date (if required) –only for
weather-compensated control units.............................. 9
•8. Language selection (if required) - only for weather-
compensated control units ............................................... 9
••• 9. Pivot down the control unit for commissioning and
maintenance work ................................................................ 10
••10. Checking the gas type......................................................... 11
•11. Gas type conversion ............................................................ 11
••• 12. Function sequence and possible faults ....................... 12
••• 13. Checking the static and supply pressure .................... 13
•14. Setting the max. output....................................................... 15
•15. Checking the balanced flue system soundness
(annular gap check) ............................................................. 15
•• 16. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 17
•• 17. Checking the burner gauze assembly........................... 18
•• 18. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 19
•• 19. Cleaning the combustion chamber/heating
surfaces and fitting the burner ........................................ 20
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 619 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 20. Checking the condensate drain and cleaning the
siphon........................................................................................ 21
•• 21. Checking the neutralising system (if installed)
•22. Testing the anode earth current with an anode
tester.......................................................................................... 21
•23. Cleaning the DHW cylinder ............................................... 22
•24. Checking and replacing the magnesium anode (if
required)................................................................................... 22
•25. Returning the DHW cylinder to use................................ 23
••• 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............................................................... 23
••• 30. Flue gas emissions test...................................................... 24
••• 31. Checking the ionisation current...................................... 26
••• 32. Checking the LPG external safety valve (if
required)
•33. Matching the control unit to the heating system ...... 27
•34. Adjusting the heating curves (only for control
units for weather-compensated operation)................. 32
•35. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 35
•36. Implementing a user check (in conjunction with
the LON system with a weather-compensated
control unit)............................................................................. 37
•37. Instructing the system user .............................................. 37
•38. Scanning and resetting the "maintenance" display 38
Steps –initial start-up, inspection and . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 619 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 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 servomotor of the
changeover valve will still be in its
centre 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
thefillprogramviacoding"2F:2".
Note
To call up coding level 1 and for
setting the coding address, see
page 39.
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
7
Initial start-up, inspection, maintenance
5692 619 GB

Venting the boiler
1. Close the shut-off valves on the pri-
mary side.
2. Connect the drain hose on valve
Awith a drain outlet.
3. Open valve Aandfillvalveinthe
heating return and vent at mains
pressure, until no sound of escap-
ingaircanbeheard.
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
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 39.
For the 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.)
8
Initial start-up, inspection, maintenance
5692 619 GB

Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fillthesiphonwithwater.
3. Fit the 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 thetimeflashesinthedisplay.
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Date"isdis-
played.
3. a/bfor the current date.
4. dto confirm.
Language selection (if required) - only for weather-compen-
sated 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.)
9
Initial start-up, inspection, maintenance
5692 619 GB

Pivot down the control unit for commissioning and mainte-
nance work
AControl unit
BClosures
CFlap
DRetaining frame
1. Open flap C.
2. Release side closures Band pivot
control unit Aforward.
3. Release the side screws and pivot
control unit Adown with its retain-
ing frame D.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 619 GB