Viessmann VITOLADENS333-F Operating instructions

VIESMANN
Service instructions
for contractors
Vitoladens 333-F
Type VP3S, 12.9/19.3 kW, 16.1/23.5 kW
Oil fired compact condensing boiler,
for the combustion of low sulphur fuel oil DIN 51603-EL-1
For applicability, see the last page
VITOLADENS 333-F
5692 779 GB 6/2008 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,
&the Code of Practice of relevant
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.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 779 GB

Working on the system
&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 main isolator.
&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 779 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 43
Code 2........................................................................................................ 45
Resetting codes to their delivered condition ................................................ 60
Service scans
Service level overview ............................................................................... 61
Temperatures, boiler coding card and brief scans ....................................... 62
Checking outputs (relay test) ...................................................................... 64
Scanning operating conditions and sensors ................................................ 65
Troubleshooting
Fault display ............................................................................................... 67
Fault codes ................................................................................................ 68
Repairs ...................................................................................................... 74
Function description
Control unit................................................................................................. 82
Extensions for external connections (accessories) ...................................... 85
Control functions ........................................................................................ 87
Remote control DIP switches ...................................................................... 93
Designs
Connection and wiring diagram –internal connections ................................ 95
Connection and wiring diagram –external connections ............................... 96
Parts lists .................................................................................................. 98
Commissioning/service reports ............................................................... 106
Specification............................................................................................. 107
Certificates
Declaration of conformity ............................................................................ 108
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 108
Keyword index .......................................................................................... 110
Index
4
Index
5692 779 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler.................................................................. 8
•03. Venting the heating system............................................... 8
•04. Filling the siphon with water............................................. 9
•05. Checking power supply connection
• • 06. Setting the time and date (if required)........................... 10
•07. Changing the language at the control unit .................. 10
••• 08. Function sequence and possible faults ....................... 11
••• 09. Pivoting down the control unit for commissioning
and maintenance work........................................................ 13
• • 10. Adjusting the standard burner settings ....................... 14
• • 11. Adjusting the oil pressure and checking the
vacuum...................................................................................... 17
• • 12. Adjusting the air volume (static burner pressure) . . . 18
•13. Cleaning the burner ............................................................. 19
•14. Replacing the nozzle and checking or adjusting
the ignition electrodes ........................................................ 20
• • 15. Cleaning and replacing the oil pump filter, if
required ................................................................................... 22
• • 16. Checking the heat exchanger for contamination...... 23
• • 17. Cleaning the heat exchanger............................................ 24
• • 18. Checking the condensate drain and cleaning the
siphon........................................................................................ 25
• • 19. Checking the neutralising system (accessories) ..... 25
• • 20. Checking the active charcoal filter (accessories) . . . . 26
•21. Testing the anode earth current with an anode
tester.......................................................................................... 26
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 779 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•22. Cleaning the DHW cylinder ............................................... 27
•23. Checking and replacing the magnesium anode (if
required)................................................................................... 28
•24. Returning the DHW cylinder into use ............................ 29
• • 25. Checking the diaphragm expansion vessel and
system pressure.................................................................... 30
••• 26. Checking all connections on the heating water
side for leaks
••• 27. Checking the burner (recording values on
page 106 of the commissioning/service report)
••• 28. Checking function of safety valves
••• 29. Checking electrical connections for tightness
•30. Matching the control unit to the heating system ...... 31
•31. Adjusting the heating curves (only for weather-
compensated control units).............................................. 36
•32. Linking the control unit to the LON ................................ 39
•33. Instructing the system user .............................................. 41
•34. Scanning and resetting the "Service" display ........... 41
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 779 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 it with water.
&Only use fill water of potable quality.
&Soften fill water with hardness exceeding 3.0 mol/m
3
, e.g. using a
small softening system for heating water (see Viessmann Vitoset price
list).
&An antifreeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the pre-charge pressure of
the diaphragm expansion vessel.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 779 GB

2. Fill the heating system via the boil-
er fill & drain valve Ain the heat-
ing return (at the connection set or
on site). (Minimum system pres-
sure 0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its cen-
tral position, and the system will be
completely filled.
3. If the control unit had already been
switched ON before filling began:
Switch ON the control unit and acti-
vate the fill program via coding
address "2F:2".
Note
To call up code 1 and for setting the
coding address, see page 43.
4. Close boiler fill & drain valve A.
5. Close the shut-off valves on the
heating water side.
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.
3. Open valve Aand the fill valve in
the heating return and vent using
mains pressure until no more air
noise can be heard.
4. Close valve Aand the fill valve in
the heating return, and open the
shut-off valves on the heating water
side.
Note
If required, also vent at tap Bduring
DHW heating.
Venting the heating system
1. Start the control unit.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 779 GB

2. Activate the venting program via
coding "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 43.
For function and sequence of the
venting program, see page 88.
When the venting program is
enabled, the display shows "Entlüf-
tung" (Venting).
3. Check the system pressure.
Filling the siphon with water
1. Remove retaining clip Aand
siphon B.
If required, push insert Cup.
2. Fill siphon Bwith water.
3. Fit siphon Band secure with
retaining clip A.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 779 GB

Setting the time and date (if required)
Note
&During commissioning, or after a
prolonged time out of use, it may be
necessary to reset the time and
date, if the time flashes in the dis-
play.
&When the unit is first taken into
operation the display is in German
(default language setting):
Time (see step 1)
Date (see step 2)
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Changing the language at the control unit
Note
When the unit is first taken into opera-
tion the display is in German (default
language setting):
Select heating circuit (see step 1.)
Outside temperature (see step 3.)
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 779 GB

3. cpress this button again,
"Außentemperatur" (outside
temperature) is displayed.
4. bfor the required language.
5. dto confirm.
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
Oil preheating
starts No
after approx.
10 min
Check the oil pre-
heater, cables
and plug-in con-
nectors
Fault
E6
Yes
Fan starts after
no more than
10 min.
Green LED on
ignition transfor-
mer flashes.
No Fault Check the oil pre-
heater, fan,
cables and plug-
in connectors
(the oil preheater
has not switched
through; the tem-
perature is not
achieved)
F9
Yes
The air pressure
switch responds No after approx. 51 s Check the air
pressure switch,
cables and plug-
in connectors
Fault
F5
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 779 GB

Yes
Ignition and oil
pump motor start No Check the ignition module and oil
pump motor,
cables and plug-
in connectors
Yes
The solenoid
valves open No Fault Check the oil sup- ply; check the so-
lenoid valves
F4
Yes
Flame signal pre-
sent
Symbol A
No Fault Check ignition
electrodes, elec-
trode gaps and
connecting lines
F4
Yes
Burner in opera-
tion.
The green LED
on the ignition
transformer is
permanently on
(a flame is recog-
nised).
For further details regarding faults,
see page 68.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 779 GB

Pivoting down the control unit for commissioning and main-
tenance work
1. Open flap A.
2. Turn both screws Bdown.
3. Release the side closures Cand
pivot control unit Dforward.
4. Release the side screws and pivot
control unit Ddown with its retain-
ing frame E.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 779 GB

5. Undo screws from cap panel F
and remove the cap panel.
6. Unhook side strapping ropes Gat
the top and pivot control unit D
down with its retaining frame E.
Note
During assembly hook strapping
ropes Gback in.
Adjusting the standard burner settings
Standard burner settings
Note
Check that the service instructions are valid for the relevant burner (see applic-
ability on the last page and the serial no. on the boiler type plate).
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 779 GB

AFlue gas test port
Rated output kW 12.9/19.3 16.1/23.5
Burner stage 2 1 2 1 2
Rated output kW 12.9 19.3 16.1 23.5
Oil burner nozzle Type 80°H LE V 80°H LE V
Make: Danfoss Gph 0.40 0.50
Oil pressure approx.
*1bar 8.0-10.5 14.0-17.5 9.0-13.5 16.0-18.5
Max. permissible va-
cuum
in oil line
bar 0.35 0.35 0.35 0.35
Oil throughput kg/h 1.05 1.58 1.53 1.92
approx. l/h 1.24 1.86 1.80 2.26
Static burner pres-
sure approx.
mbar 8.0-10.5 15.5-19.5 11.0-15.5 17.5-21.0
CO2content approx.
&Test value w/o cap % 12.2-13.4 12.2-13.2
&Test value with cap % 12.7-13.9 12.7-13.7
Nozzle gap "a" mm 3.0
+0.2/-0.3
1.5
+0.2/-0.3
(see page 20)
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 779 GB
*1Due to nozzle tolerances and varying oil characteristics, the oil pressure may vary from
the values shown.

!Please note
An incorrectly adjusted nozzle gap "a" can result in irregular operation of
the burner and even a fault shutdown.
Always maintain the stated dimension and check in accordance with the
details on page 20.
Installation position, oil preheater
Position the oil preheater in the recess of the mixer facility in accordance with
the diagram.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 779 GB

Adjusting the oil pressure and checking the vacuum
Oil pump; make: Danfoss,
type BFP 52
1. Insert the pressure gauge (range
0 - 25 bar) into test port "P" A
and the vacuum gauge (range 0 -
1 bar) into test port "V" B.
Note
Seal the pressure and vacuum
gauges only with copper or alumi-
nium gaskets or with O-rings.
Never use tape to seal these
joints.
2. Start the boiler.
3. Press Kand dsimultaneously
for approx. 2 s.
"Relay test" is shown in the dis-
play.
After approx. 4 s the display
shows "Burner st 1 ON".
4. Where vacuum measures higher
than 0.35 bar, check the filter for
contamination or check the pipe
route.
5. If required, adjust the oil pressure
for stage 1 at pressure adjusting
screw Cof the oil pump (for
standard values, see page 15).
6. Check the actual emission values
after adjusting the oil pressure.
7. Select burner stage 2 with a.
"Burner st 1 + 2 ON" is shown on
the display.
8. If required, adjust the oil pressure
for stage 2 at pressure adjusting
screw Dof the oil pump.
9. Check the actual emission values
after adjusting the oil pressure.
10. After testing, press d.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 779 GB

Adjusting the air volume (static burner pressure)
1. Start the boiler.
2. Remove plug Afrom the test port.
3. Connect the U-shaped pressure
gauge to test port A.
4. Press Kand Fsimultaneously
until "Speed stage 1" and a value
between 1 and 255 are displayed.
5. Change the value with a/buntil
the static burner pressure dis-
played by the U-shaped pressure
gauge and the CO2flue gas con-
tent correspond to the values in the
table on page 15.
6. Confirm the set value with d.
Note
The control unit changes automati-
cally to burner stage 2. The display
shows "Speed stage 1 + 2 " and a
value between 1 and 255.
7. Repeat steps 4 and 5 for burner
stage 2.
8. Check the set values.
9. Seal test connector Aagain with
the previously removed plug.
Note
Do not seal the connector next to
test connector A.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 779 GB

Cleaning the burner
1. Undo nuts, remove the lid with
mixer equipment Aand secure in
the maintenance position.
2. Pull the leads off ignition electro-
des B.
3. Undo Allen screw Cand remove
rifling facility D.
4. Clean the restrictor, dosing ring
and ignition electrodes.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 779 GB

Replacing the nozzle and checking or adjusting the ignition
electrodes
1. Undo nozzle Ewhilst holding the
oil preheater. Prevent the formation
of bubbles.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 779 GB