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

Checking the gas type
Note
In the delivered condition, the Vitodens 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
(43.2
to 58.0 MJ/m
3
).
1. Determine the gas type and Wobbe
index (Wo) by asking your local
mains gas or LPG supplier.
2. Compare the gas category (type)
and group with the details on the
burner label.
3. The burner must be converted
according to the details provided
by the mains gas or the LPG sup-
plier to match the fuel provided, if
these details do not match.
Conversion kit installation
instructions.
Wobbe index range after conver-
sion:
&Natural gas LL
10.0 to 13.1 kWh/m
3
(36.0 to
47.2 MJ/m
3
)
&LPGP(only26kW)
21.4 to 22.5 kWh/m
3
(76.9 to
81.0 MJ/m
3
)
4. When converting to LPG (only
26 kW)
Adjust coding address "1E:1" (see
page 39).
5. Record the gas type in the service
report on page 117.
Gas type conversion
Gas restrictor installation
instructions
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 619 GB

Gas restrictor allocation
Rated output kW 13 26
Gas restrictor, internal 7
Gas
&Natural gas E mm 4.8 5.95
&Natural gas LL mm 5.3 6.73
&LPG P mm —4.4
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 plugs
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 plugs, check
fan
Yes
Ignition No Fault F4 Check ignition
module (control
voltage 230 V
across plugs
"X2.1" and
"X2.2")
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 619 GB

Yes
Gas combination
valve opens No Fault F4 Check the gas combination valve
(control voltage
230 V); check the
gassupplypres-
sure
Yes
Ionisation cur-
rent builds
(higher than
2µA)
Symbol A
No Fault F4 Check ionisation
current, check
electrode adjust-
ment and gas
pipe for airlocks.
Yes
Burner starts No Stops below set
boiler water tem-
perature and re-
starts immedi-
ately
Check flue gas
system sound-
ness (flue gas re-
circulation),
check gas flow
pressure
For further details regarding faults, see page 69.
Checking the static and supply pressure
Danger
CO build-up as a result of incorrect burner setting can have serious
health implications.
Carry out a CO test prior to, and after, work on gas equipment.
Operation with LPG (only 26 kW)
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 619 GB

1. Close the gas shut-off valve.
2. Release screw Ainside test nip-
ple "PE" on the gas combination
valve, but do not remove it; then
connect the pressure gauge.
3. Open the gas shut-off valve.
4. Record the staticpressureand
record it in the service report on
page 117.
Set value: max. 57.5 mbar
5. Start up 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"toresetthe
burner.
6. Check the supply (flow) pressure.
Set value:
&Natural gas: 20 mbar
&LPG (only 26 kW): 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 117.
Taketheactionshowninthetable.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG (only 26 kW)
Measures
below 17.4 mbar below 42.5 mbar Never start up. Notify your mains gas
or LPG supplier.
17.4 to 57.5 mbar 42.5 to 57.5 mbar Start up the 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
inlet pressure to 20 mbar for natural
gas or 50 mbar for LPG. Notify your
mains gas or LPG supplier.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 619 GB

8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test nipple A
with the screw.
9. 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.
Setting the max. output
Note
The maximum output can be limited for heating operation.Youcanlimitthe
output via the modulation range.
1. Start up the boiler.
2. Press K+Fsimultaneously:
"100" flashes (cor-
responds to 100%
of rated output)
and "A"isdis-
played.
On weather-com-
pensated control
units, the display
additionally shows
"Max. output".
a/bfor the required
valuein%ofrated
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
thetypeplateontopoftheboiler.
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 (pressure test)
during commissioning by the flue gas inspector.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 619 GB

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 aperture (ventila-
tion air)
Thefluepipeisdeemedtobesoundif
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 check
the flue pipe at a static pressure of
200 Pa.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 619 GB

Removing the burner and checking the burner gasket
(replace gasket every two years)
ANuts
BDifferential pressure sensor
CBurner gasket
DGas supply pipe
EGas train
FIonisation electrode
GEarth stud
HFan motor
KIgnition device
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 off electrical cables from fan
motor H, differential pressure sen-
sor B,gasvalveE, ionisation
electrode F, ignition unit Kand
earth stud G.
4. Release gas supply pipe fitting D.
5. Release four nuts Aand remove
the burner.
!Please note
Prevent damage to the wire
mesh.
Never rest the burner on the
gauze assembly.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 619 GB

6. Check the burner gasket Cfor
damage.
Generally replace the burner gas-
ket every 2 years.
Checking the burner gauze assembly
Replace the burner gauze assembly if the wire mesh is damaged.
ATorx screws
BBurner gauze
CBurner gauze gasket
DIonisation electrode
EIgnition electrodes
1. Remove electrodes Dand E.
2. Release the six Torx screws A
and remove the burner gauze
assembly B.
3. Remove the old burner gauze gas-
ket C.
4. Insert a new burner gauze assem-
bly with a new gasket and secure it
with six Torx screws.
Note
Torque: 3.5 Nm
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 619 GB

Checking and adjusting the ignition and ionisation electro-
des
AIgnition electrodes BIonisation electrode
CGasket
1. Check electrodes Aand Bfor
wear and contamination.
2. Clean the electrodes with a small
brush (not with a wire brush) or
emery paper.
!Please note
Never damage the
wire mesh.
3. Check clearances. If the gaps are
not as specified or the electrodes
are damaged, replace and align the
electrodes together with new gas-
kets C. Tighten the electrode fix-
ingscrewswith2Nm.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 619 GB

Cleaning the combustion chamber/heating surfaces and fit-
ting the burner
1. If required, clean the combustion
chamber and heating surfaces A
withabrushorflushwithwater.
!Please note
Scratches on parts which
are in contact with flue
gases can lead to corrosion.
Only use plastic brushes
and NOT wire brushes.
2. Apply a solvent/potassium-free
cleaning agent if residues remain:
&Remove soot deposits with alka-
line cleaning agents with addi-
tional surfactants (e.g.
Fauch 600).
&Remove coatings and surface
discolouration (yellow-brown)
with slightly acidic, chloride-free
cleaning agents based on phos-
phoric acid (e.g. Antox 75 E).
&Thoroughly flush with water.
Note
Fauch 600 and Antox 75 E are sup-
plied by
Hebro Chemie GmbH
Rostocker Straße 40
D 41199 Mönchengladbach
3. Install the burner and torque nuts
diagonally with 4 Nm.
4. Secure the gas supply pipe with a
new gasket.
5. Check the gas connections for
soundness.
Danger
Escaping gas leads to a risk
of explosions.
Check all fittings for sound-
ness.
6. Connect the electrical cables/leads
to each corresponding component.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 619 GB