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