Viessmann VITODENS 333 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitodens 333
Type WS3A, 6.6 to 26.0 kW
Compact gas fired condensing boiler
natural gas and LPG version
See applicability on the last page
VITODENS 333
5692 548 GB 3/2004 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.
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 548 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 and check that is is no longer
'live', e.g. by removing a separate
fuse or by means of a mains electri-
cal isolator.
&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 548 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 the coding to the as delivered condition ...................................... 61
Service scans
Service level summary................................................................................ 62
Temperatures, boiler coding card and brief scans ....................................... 63
Testing outputs (relay test).......................................................................... 67
Scanning operating conditions and sensors ................................................ 69
Troubleshooting
Call up fault history of fault codes................................................................ 72
Call up current fault codes .......................................................................... 72
Checking and acknowledging faults ............................................................ 74
Repairs ...................................................................................................... 84
Function description
Constant temperature control unit ............................................................... 95
Weather-compensated control unit.............................................................. 97
Internal extension H1.................................................................................. 99
Extensions for external connections (accessory)......................................... 100
Control functions ........................................................................................ 103
Designs
Connection and wiring diagrams –internal connections .............................. 108
Connection and wiring diagrams –external connections.............................. 110
Parts lists .................................................................................................. 112
Commissioning/service reports............................................................... 120
Specification............................................................................................. 126
Certificates
Declaration of conformity ............................................................................ 127
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 128
Keyword index .......................................................................................... 129
Index
4
Index
5692 548 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. Pivot the control unit down to carry out
commissioning and maintenance work........................ 10
••• 8. Function sequence and possible faults ....................... 10
••9. Checking the gas type......................................................... 12
•10. Changing the gas type (see separate installation
instructions)
••• 11. Checking static and supply pressure ........................... 13
••• 12. Checking the CO2settings ................................................ 15
•13. Setting the max. output ...................................................... 17
••• 14. Check all connections on the primary and DHW
side for leaks
••• 15. Checking the burner (recording values on page
120 of the commissioning report)
•16. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 18
•• 17. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 19
•• 18. Checking the burner gauze assembly........................... 20
•• 19. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 21
Steps - initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 548 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 20. Cleaning the combustion chamber/Cleaning the
heating surfaces and installing the burner ................. 22
•• 21. Checking the condensate drain and cleaning the
siphon........................................................................................ 23
•• 22. Checking the neutralising system (if installed)
•23. Testing anode earth current with an anode test
device ........................................................................................ 23
•24. Cleaning the DHW cylinder ............................................... 24
•25. Checking and replacing the magnesium anode (if
required)................................................................................... 25
•26. Taking the DHW cylinder back into use ........................ 25
••• 27. Checking the diaphragm expansion vessel and
system pressure
••• 28. Checking the function of all safety valves
••• 29. Checking tightness of electrical connections
••• 30. Checking all gas equipment for soundness at
operating pressure............................................................... 26
••• 31. Checking the ionisation current...................................... 26
••• 32. Checking the external LPG safety valve (if
installed)
•33. Matching the control unit to the heating system ...... 27
•34. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 32
•35. Implementing a user check (in conjunction with
the LON system) .................................................................... 33
•36. Adjusting heating curves (only for weather-
compensated control units).............................................. 34
•37. Instructing the system user .............................................. 37
•38. Scanning and resetting the maintenance display .... 37
Steps - initial start-up, inspection and maintenanc . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 548 GB

Filling the heating system
1. Check the charge pressure of the
diaphragm expansion vessel.
2. Close the gas shut-off valve.
3.
!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 pota-
ble quality.
&Soften fill water harder
than 20 cdH (3.58 mmol/l).
For suitable means of
water softening, see the
Vitoset pricelist.
&An anti-freeze additive
suitable for heating sys-
temscanbemixedwith
the fill water.
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
The diverter valve actuator will be
in the central position, and the sys-
tem will be completely filled, if the
control unit has not been switched
ON before the system was filled.
4. If the control unit had already been
switched ON before filling began:
Start the control unit and in code 1,
set coding address 2F:2.
The diverter valve will then be in its
central position.
Note
To call up code 1 and for setting the
coding address, see page 39.
Whilst filling is in progress, the dis-
play shows bF (constant tempera-
ture control unit) or Filling
(weather-compensated control
unit).
Continue filling the system.
5. Close the boiler fill & drain valve.
6. Set coding address 2F:0.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 548 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 104.
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 548 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.
2. Select the required language with
b.
3. Confirm with d.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 548 GB

Pivot the control unit down to carry out commissioning and
maintenance work
1. Open flap A.
2. Release the side closures Band
pivot control unit Cforward.
3. Release the side screws and pivot
control unit Cdown with its retain-
ing frame D.
Function sequence and possible faults
For further details regarding faults, see page 74.
Display screen Remedy
Control unit
issues a heat
demand
No Set value
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 548 GB

Yes
Fan starts
No
After approx.
51 seconds
Check cables and
plug-in connec-
tions
Fault
F9
Yes
Differential pres-
sure sensor
enables start
(0.75 V across
terminals X8.5
and X8.6)
No
After approx.
51 seconds
Check fan cables
and fan plug-in
connections,
check fan
Fault
E6
Yes
Ignition No Fault Check the ignition
module (control
voltage 230 V
across plugs X2.1
and X2.2)
F4
Yes
Gas combination
valve opens No Fault Check the gas
combination valve
(control voltage
230 V), check the
gassupplypres-
sure
F4
Yes
Ionisation cur-
rent builds
(higher than
5µA) No
Fault Check electrode
adjustment and
check the gas
pipe for airlocks
Symbol AF4
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 548 GB

Yes
Operational bur-
ner
Stops below set
boiler tempera-
ture and immedi-
ately restarts
again
Check flue gas
system for sound-
ness (flue gas
recirculation),
check gas flow
pressure
Checking the gas type
1. Enquire about the gas type and
Wobbe index (Wo) from your local
mains gas or LPG supplier.
Note
In the as 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.
Seeseparateconversionkit
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.
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 548 GB

5. Record the gas type in the commis-
sioning/service report on page
120.
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.
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.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 548 GB

6. Check the supply (flow) pressure; it
should be
&20 mbar for natural gas,
&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.
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.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 548 GB

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
&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.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 548 GB

1. Connect a flue gas analyser at the
flue gas aperture Aon the boiler
adaptor.
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 (possibly
replace the burner).
5. Enter actual values into the service
report.
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.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 548 GB

7. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 15 (possibly
replace the burner).
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. The control pressure acts as standard value for set-
ting the required output.
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 548 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.
Thefluepipeisdeemedtobesound,
if the CO2concentration of the com-
bustion 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, carry out a pressure
testonthefluepipeatastaticpres-
sure of 200 Pa.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 548 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 the 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 548 GB

Checking the burner gauze assembly
Replace the burner gauze assembly if
the wire mesh is damaged.
1. Remove electrodes A.
2. Remove thermal insulation ring B.
3. Release the six Torx screws C
and remove the burner gauze
assembly D.
4. Remove the old gauze assembly
gasket E.
5. Insert a new burner gauze assem-
bly with a new gasket, and secure
with six Torx screws.
Note
Torque: 3.5 Nm
6. Refit a new thermal insulation
ring B.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 548 GB