Service instructions VIESMANN for heating engineers Vitodens 333 Type WS3A, 6.6 to 26.
Safety instructions Safety instructions 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. & all legal instructions regarding the prevention of accidents, & the TRGI, TRF and special regulations, e.g.
Safety instructions Safety instructions (cont.) If you smell flue gas Danger Flue gas may lead to life-threatening poisoning. & Shut down the heating system. & Ventilate the boiler room. & Close all doors leading to the living space. Repair work & Isolate the system from mains supply and check that is is no longer 'live', e.g. by removing a separate fuse or by means of a mains electrical isolator. & Safeguard the system against unauthorised reconnection.
Index Index Initial start-up, inspection, maintenance Steps - initial start-up, inspection and maintenance ..................................... Further details regarding the individual steps .............................................. 5 7 Coding Code 1........................................................................................................ 39 Code 2........................................................................................................
Initial start-up, inspection, maintenance Steps - initial start-up, inspection and maintenance For further instructions on individual steps, see pages indicated Commissioning steps Inspection steps Maintenance steps ! • • • • • • ! ! 1. Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2. Venting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection, maintenance Steps - initial start-up, inspection and maintenanc . . . (cont.) Commissioning steps Inspection steps Maintenance steps ! • ! • 20. Cleaning the combustion chamber/Cleaning the heating surfaces and installing the burner . . . . . . . . . . . . . . . . . 22 • • 21. Checking the condensate drain and cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection, maintenance Further details regarding the individual steps 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 potable quality. & Soften fill water harder than 20 cdH (3.58 mmol/l).
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 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 A and fill valve in the heating return, and vent at mains pressure, until no sound of escaping air can be heard anymore. 4. Close valve A and fill valve in the heating return, and open the primary shut-off valves. Venting the heating system 1.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Filling the siphon with water 1. Remove the retaining clip and siphon A. 2. Fill the siphon with water. 3. Fit siphon A and secure with the retaining clip. Language selection (if required) - only for the weather-compensated control units 1. Press c. 3. Confirm with d. 5692 548 GB 2. Select the required language with b.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Pivot the control unit down to carry out commissioning and maintenance work 1. Open flap A. 3. Release the side screws and pivot control unit C down with its retaining frame D. 2. Release the side closures B and pivot control unit C forward.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Yes Fan starts No After approx. 51 seconds Fault Check cables and plug-in connections F9 Yes Differential pressure sensor enables start (0.75 V across terminals X8.5 and X8.6) No After approx. 51 seconds Fault E6 Check fan cables and fan plug-in connections, check fan Yes Ignition No Fault F4 Check the ignition module (control voltage 230 V across plugs X2.1 and X2.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Yes Operational burner Stops below set boiler temperature and immediately restarts again Check flue gas system for soundness (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, Vitodens 333 is set up for natural gas E.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 5. Record the gas type in the commissioning/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 condition of the system. Operation with LPG Flush the LPG tank twice during commissioning/replacement.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 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 service report. Take the action shown in the table. Supply (flow) pressure for natural gas below 17.4 mbar Supply (flow) pressure for LPG below 42.5 mbar 17.4 to 57.5 mbar 42.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO2 settings 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 CO 2 level at the boiler adaptor. Note The MatriX burner for Vitodens 333 is preset for the entire gas group. Therefore, the burner requires no further setting or adjustment.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Connect a flue gas analyser at the flue gas aperture A on the boiler adaptor. 2. Open the gas shut-off valve, commission the boiler and create a heat demand. 3. Select the lower rated output. Constant temperature control unit: & Press both keys 9 and d simultaneously until the display shows 1. Weather-compensated control unit: & Press both keys 9 and d simultaneously until the display shows Relay test.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 7. Check the CO 2 content. Should the actual value deviate by more than 1 % from the above range, implement 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.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the balanced flue system for soundness (annular gap check) 5692 548 GB A Combustion 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 commissioning by the flue gas inspector.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 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 electrical supply. 2. Close the gas shut-off valve and safeguard against reopening. 3. Pull electrical cables off fan motor A, differential pressure sensor B, gas valve C, ionisation electrode D, ignition unit E and earth F. 5.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 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. Note Torque: 3.5 Nm 6. Refit a new thermal insulation ring B. 5692 548 GB 4. Remove the old gauze assembly gasket E. 5.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking and adjusting the ignition and ionisation electrodes A Ignition electrodes B Ionisation electrode 1. Check the electrodes for wear and contamination. 3. Check all clearances. If the gaps are not as specified or the electrodes are damaged, replace and align the electrodes together with new gaskets A. Tighten the electrode fixing screws with 2 Nm. 2.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the combustion chamber/Cleaning the heating surfaces and installing the burner 1. If required, clean combustion chamber and heating surfaces A with a brush or flush with water. ! Important information Scratches on parts which are in contact with flue gases, can lead to corrosion. Only use plastic brushes and NOT wire brushes.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 4. Check the gas connections for soundness. Danger Escaping gas leads to a risk of explosion. Check all fittings for soundness. 5. Connect the electrical cables/leads to each corresponding component. Checking the condensate drain and cleaning the siphon 1. Check at siphon A, that the condensate can freely drain. 2. Remove the retaining clip and the siphon. 3. Clean the siphon. 4.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove cover A. 2. Pull earth cable B from connecting tab C. 3. Connect the test equipment (up to 5 mA) in series between connecting tab C and earth cable B. & The anode is OK if the indicated current is >0.3 mA. & Visually inspect the anode, if the current measures < 0.3 mA or if there is no current at all (see page).
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 5. Remove hard deposits that cannot be removed by a high pressure cleaner, with a chemical cleaning agent. ! Important information Never use hydrochloric cleaning agents. 6. Thoroughly flush the DHW cylinder after cleaning. Checking and replacing the magnesium anode (if required) Check the magnesium anode. We recommend you change the magnesium anode if it has been reduced down to 10 to 15mm Ø.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking all gas equipment for soundness at operating pressure Danger Escaping gas leads to a risk of explosion. Check gas equipment for soundness. Checking the ionisation current 1. Pull the line off and connect test equipment (adaptor line available as accessory). 2. Set the upper rated output. Constant temperature control unit: & Press K and d simultaneously for at least 2 seconds.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 4. After testing, press d. 5. Record the actual value in the service report. Matching the control unit to the heating system Note The control unit must be matched to the system equipment. Various system components are automatically recognised by the control unit, and codes are automatically set. & For selection of an appropriate design, see the following diagrams. & For coding steps, see page 39.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Required coding Operation with LPG Address 1E:1 System design 3 With one heating circuit without mixer A1 and one heating circuit with mixer M2 Note The volume flow of the heating circuit without mixer must be at least 30 % greater than the volume flow of the heating circuit with mixer.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Connecting the control unit to the LON system (only for weather-compensated control units) The LON communication module (accessory) must be plugged in. Installation instructions LON communication module Note Data transfer via the LON system can take 2 to 3 minutes. Setting up LON user numbers Adjust the user number via coding address 77 (see below). In a LON system, the same number cannot be allocated twice.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 5. Press L and d simultaneously for approx. 1 second. User check completed. Adjusting heating curves (only for weather-compensated control units) Settings in the delivered condition: & Slope = 1.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Changing slope and level 1. Modify the slope in code 1 with coding address d3 (see page 39). Adjustable value 2 to 35 (equals slope 0.2 to 3.5). 2. Modify the slope in code 1 with coding address d4 (see page 39). Value adjustable from –13 to +40 K. A Changing the slope B Changing the level Adjusting the set room temperature Standard room temperature: 5692 548 GB 1.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 2. Adjust the set day temperature with rotary selector ts. The value will be automatically adopted after approx. 2 seconds. Accordingly, the heating curve is adjusted along set room temperature axis C, which results in modified start/shutdown characteristics of the heating circuit pumps, if the heating circuit pump logic is activated.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 2. Call up the set night temperature with E. 3. Change this value with a and b. 4. Confirm the set value with d.
Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Press c. Maintenance scan is activated. After maintenance has been carried out 2. Scan maintenance messages with a or b. 1. Reset code 24:1 to 24:0. The red fault indicator is extinguished. 3. Press d, for weather-compensated control units also confirm the display "Acknowledge: Yes" with d. "Maintenance" is cancelled from the display, and the red fault indicator continues to flash. 2.
Coding Code 1 Call up code 1 1. Press K and L simultaneously for approx. 2 seconds. 2. Select the required coding address with a or b; the address flashes. Confirm with d; the value flashes. Note Codes are displayed in plain text on weather-compensated control units. Codes, which are not relevant because of the equipment level of your heating system or because of settings of other codes, will not be displayed. 3. Change this value with a and b; confirm with d.
Coding Code 1 (cont.) Coding in the as delivered condition Address: value Gas type 1E:0 Function mode Operation with natural gas Venting/filling 2F:0 Ventilation program/filling program inactive User no. 77:1 LON user number Coding change Address: value Possible change 1E:1 Operation with LPG 2F:1 2F:2 Venting program active Filling program active 77:2 to 77:99 LON user number, adjustable from 1 to 99: 1-4 = boiler 5 = cascade 10 - ... = Vitotronic 050 99 = Vitocom Summer econ.
Coding Code 1 (cont.) Coding in Function mode the as delivered condition Address: value Max. flow. temp. M2 C6:75 * 1Electronic maximum flow temperature limit at 75 °C Slope A1 d3:14 * 1Heating curve slope = 1.4 Slope M2 d3:14 Level A1 d4:0 Possible change C6:1 to C6:127 Maximum limit adjustable from 1 to 127 °C d3:2 to d3:35 Heating curve slope adjustable from 0.2 to 3.5 (see page 34) * 1Heating curve slope = d3:2 1.4 to d3:35 Heating curve slope adjustable from 0.2 to 3.
Coding Code 2 (cont.) 4. Press L and G simultaneously for approx. 1 second. Coding is terminated. Overall summary The coding addresses are grouped in accordance with the following function ranges. The respective function range is displayed. Scroll through the ranges in the following sequence with a or b.
Coding Code 2 (cont.) Codes Coding in Function mode the as delivered condition Address: value System design 00 :2 System design 1: 1 heating circuit without mixer A1, with DHW heating Boiler/burner 06:...
Coding Code 2 (cont.
Coding Code 2 (cont.) Coding 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Internal Heating circirculacuit pump tion pump Heating circuit without mixer Control Control funct. funct. Control Control funct. funct. Control OFF funct. Control OFF funct. Control OFF funct. Control OFF funct. OFF Control funct. OFF Control funct. OFF Control funct. OFF Control funct. OFF OFF OFF OFF OFF OFF OFF OFF Cylinder loading pump OFF Control funct. OFF OFF Control funct. Control funct. Control funct.
Coding Code 2 (cont.) Internal circulation pump 0 8 Control funct. Control funct. Control funct. Control funct. Control funct. Control funct. Control funct. Control funct. OFF 9 OFF 10 OFF 11 OFF 12 13 14 15 16 OFF OFF OFF OFF ON 17 ON 18 ON 19 ON 20 ON 1 2 3 4 5 6 7 46 Heating circuit pump Heating circuit without mixer Control funct. Control funct. Control funct. Control funct. OFF Heating circuit pump Heating circuit with mixer Control funct. Cylinder loading pump Control funct.
Coding Code 2 (cont.
Coding Code 2 (cont.) 60:10 62:2 Function mode Coding change Address: value Possible change DHW cylinder loading: Starting point -2.5 K Stopping point +2.
Coding Code 2 (cont.
Coding Code 2 (cont.
Coding Code 2 (cont.
Coding Code 2 (cont.) Function mode Coding change Address: value * 1Monitoring LON users 9C:0 When there is no response from a user, values defaulted inside the control unit continue to be used for a further 20 minutes. Only then will a fault message be triggered. 9F:8 * 1Differential temperature 8 K; only in conjunction with a mixer circuit Boiler circuit, mixer circuit A0:0 * 1Without remote control 9C:5 to 9C:60 52 for weather-compensated control unit.
Coding Code 2 (cont.) Coding in the as delivered condition Address: value A3:2 Function mode Coding change Address: value Outside temperature A3:-9 below 1 °C: Heating cir- to cuit pump ON A3:15 Outside temperature above 3 °C: Heating circuit pump OFF Possible change Heating circuit pump ON/ OFF (see the following table) 5692 548 GB Note When selecting a value below 1 °C there will be a risk of pipes outside the thermal insulation envelope of the house freezing-up.
Coding Code 2 (cont.) Coding in Function mode the as delivered condition Address: value Boiler circuit, mixer circuit A4:0 * 1With frost protection Coding change Address: value Possible change A4:1 No frost protection, adjustment only possible if code "A3 : -9" is selected. Note When selecting a value below 1 °C there will be a risk of pipes outside the thermal insulation envelope of the house freezing-up. The standby mode, in particular, should be observed, e.g. during holidays.
Coding Code 2 (cont.) Parameter address A5:... 7 to 15 With heating circuit pump logic function: Heating circuit pump OFF, if AT > RTSet - 1 K AT > RTSet - 9 K 5692 548 GB Coding in Function mode the as delivered condition Address: value Boiler circuit, mixer circuit A6:36 * 1Extended economy circuit inactive *1 Only Coding change Address: value Possible change A6:5 to A6:35 Extended economy circuit active, i.e.
Coding Coding in the as delivered condition Address: value A7:0 Function mode Coding change Address: value Possible change * 1Without mixer econ- A7:1 With mixer economy function (extended heating circuit pump logic): Heating circuit pump also OFF, if the mixer was closed for longer than 20 minutes.
Coding Code 2 (cont.
Coding Code 2 (cont.) With heating circuit pump logic function: Heating circuit pump OFF, if active RTActual > RT Set - 1 K; passive RTActual < RT Set - 2 K active RTActual > RT Set - 2 K; passive RTActual < RT Set - 3 K Function mode Coding in the as delivered condition Address: value Boiler circuit, mixer circuit C5:20 * 1Electronic minimum flow temperature limit in standard mode 20 °C C6:74 d3:14 d4:0 * 1Electronic maximum flow temperature limit 74 °C * 1Heating curve slope = 1.
Coding Code 2 (cont.) Coding in the as delivered condition Address: value E5:0 E6:65 E7:30 E8:1 E9:45 Function mode Coding change Address: value Possible change No display correction of the actual room temperature * 2Without variable speed circuit pump E2:99 Display correction +4.9 K E5:1 With variable speed circuit pump; automatic recognition Maximum speed adjustable from 0 to 100 % of max. speed * 2Max. speed of the variable speed pump = 65 % of max. speed in standard mode * 2Min.
Coding Code 2 (cont.) F2:8 F5:12 *3 Only Function mode * 3Time limit for party operation 8 hours or external operating mode changeover via push button * 4 * 5* 5Run-on time of the internal circulation pump in heating mode Coding change Address: value F1:6 to F1:15 F2:0 F2:1 to F2:12 F5:0 F5:1 to F5:20 Possible change must contain the following heat-up details: & Heat-up data with respective flow temperatures & Max.
Coding Code 2 (cont.) Coding in the as delivered condition Address: value Function mode Coding change Address: value F6:0 * 6* 6In the "DHW only" F6:1 to F6:24 operating mode, the internal circulation pump is permanently OFF F6:25 F7:0 * 6* 6Internal circulation pump is permanently OFF in operating mode "Standby mode" F7:1 to F7:24 F7:25 Possible change 20 minutes In the "DHW only" operating mode, the internal circulation pump will be started 1 to 24 times per day for 10 minutes respectively.
Service scans Service level summary Exit Press d. Page 63 Press d. 67 Press d. 17 Press c. Press d. 69 37 – – – – – – – – – – – – – – 5692 548 GB Function Key combination Temperatures, boiler cod- Press K and G simultaing card and brief scans neously for approx. 2 seconds Relay test Press K and d simultaneously for approx. 2 seconds Max. output (heating Press K and F simultamode) neously for approx. 2 seconds Operating condition Press c.
Service scans Temperatures, boiler coding card and brief scans Weather-compensated control unit 1. Press K and G simultaneously for approx. 2 seconds. 2. Select the required scan with a and b. 3. Press d. The following values can be scanned, subject to the actual equipment level: Slope A1 – Level A1 Slope M2 – Level M2 & Adj. outside temp. & Actual outside temp. & Set boiler temp. & Actual boiler temp. & Set DHW temp. & Actual DHW temp. & Actual DHW outlet temp. & Set DHW outlet temp. & Set flow temp.
Service scans Temperatures, boiler coding card and brief scans (cont.) Display screen Brief scan 2 3 4 5 Display KM BUS users Max. demand temperature Software Software Software Software version version version version Mixer Solar LON Ext. extenextencontrol system sion sion kit unit Type Boiler type Burner control unit N/A External hook-up 0 to 10 V Display in % Software Max.
Service scans Temperatures, boiler coding card and brief scans (cont.) Display screen Brief scan 7 8 N/A N/A Internal circultion pump Variable Software speed version pump variable 0: excl. speed 1: Wilo pump 2: Grundfos Heating circuit 1 (boiler circuit A1) Remote Software control version 0: excl. Remote 1: Vitocontrol trol 200 2: Vitotrol 300 Heating circuit pump boiler circuit A1 Variable Software speed version pump variable 0: excl.
Service scans Temperatures, boiler coding card and brief scans (cont.) Display screen Brief scan 0 1 E 3 A 4 5 0: No ext. blocking 1: Ext. blocking present Software version Operating interface Software version Cascade module External hook-up 0 to 10 V Display in % Set boiler temperature at the boiler temperature sensor Highest demand temperature Burner control unit type Boiler type Set cylinder temperature at the cylinder temperature sensor (current value) Max.
Service scans Temperatures, boiler coding card and brief scans (cont.) Display screen Brief scan d Variable speed pump 0: excl. 1: Wilo 2: Grundfos Software version variable speed pump Testing outputs (relay test) Weather-compensated control unit 1. Press K and d simultaneously for approx. 2 seconds. Relay test is activated. 2. Select the relay outputs with a and b. 3. Press d. Relay test is completed.
Service scans Testing outputs (relay test) (cont.) Display Solar pump ON Explanations Vitosolic Constant temperature control units 1. Press K and d simultaneously for approx. 2 seconds. Relay test is activated. 2. Select the relay outputs with a and b. 3. Press d. Relay test is completed.
Service scans Scanning operating conditions and sensors Weather-compensated control unit 5692 548 GB 1. For two heating circuits – select heating circuit: & Press a. 1r flashes on the display. & Select heating circuit A1 (heating circuit without mixer): Press d. & Select heating circuit M2 (heating circuit with mixer): – Press a. – 2r flashes on the display. – Press d. 2. Press c. 3. Select the required operating condition scan with a or b. 4. Press c.
Service scans Scanning operating conditions and sensors (cont.) Operating condition display (subject to system equipment level) Date Burner OFF or ON Int. pump OFF or ON Int. output OFF or ON Heating pump OFF or ON Cylinder loading pump OFF or ON DHW circulation pump OFF or ON Central fault display OFF or ON Mixer, mixer open or mixer close Solar pump OFF or ON Solar pump ...
Service scans Scanning operating conditions and sensors (cont.
Troubleshooting Call up fault history of fault codes The last 10 faults are saved and may be called up. 1. Press G and d simultaneously for approx. 2 seconds. 2. Call up the individual fault codes with a or b. Order in which fault codes occur 1 . . . 10 Fault code Latest fault code . . . 10. last fault code All saved fault codes can be deleted with e. 3. Press d. Call up current fault codes Red fault indicator U flashes for all faults.
Troubleshooting Call up current fault codes (cont.) Control unit faults 1. Find current fault with c. 2. Select additional fault codes with a and b. 3. Acknowledge fault The fault can be acknowledged with d. The fault message in the display will be hidden, but red fault indicator A continues to flash. A new fault message will be shown in the display if an acknowledged fault is not removed by 07:00 h the following day. Fault on the burner control unit 1. Find current fault with c. 2.
Troubleshooting Call up current fault codes (cont.) 4. E in the display indicates that the burner control unit is locked out. After the fault has been removed, acknowledge by pressing reset E. Fault display design A Fault symbol B Plain text fault display (only for weather-compensated control units) C Fault number D Fault code 1. Calling up acknowledged fault messages Press d for approx. 3 seconds. The fault will then be displayed.
Troubleshooting Checking and acknowledging faults (cont.) Constant temperature control units Note The fault can be acknowledged with d. The fault message in the display will be hidden, but the red fault indicator U continues to flash. A new fault message will be displayed if an acknowledged fault is not removed by the following morning. 5692 548 GB Calling up acknowledged fault messages Press d for approx. 2 seconds; select the acknowledged fault with a or b. Fault code Const.
Troubleshooting Checking and acknowledging faults (cont.) Weath. comp.
Troubleshooting Checking and acknowledging faults (cont.) Fault code Const. in the display 9C X Weath. comp.
Troubleshooting Checking and acknowledging faults (cont.) Fault code Const. in the display bC Weath. comp.
Troubleshooting 5692 548 GB Checking and acknowledging faults (cont.) Fault code Const. in the display C6 Weath. comp. X C7 X X Cd X X CE X X CF X dA X db X System characteristics Control mode, max. pump speed Cause Remedy Check coding address E5 settings; check the heating circuit pump DIP switch settings Control Communication Check coding mode, fault - variable address E5 max.
Troubleshooting Checking and acknowledging faults (cont.) Weath. comp.
Troubleshooting Checking and acknowledging faults (cont.) Weath. comp. X F3 X X F4 X X System Cause Remedy characteristics Burner in Temperature limiter Check the fault state has responded heating system water level. Check the circulation pump. Vent the heating system. Check the temperature limiter and leads. Press E. Burner in The flame signal is Check the fault state already present at ionisation burner start electrode and leads. Press E.
Troubleshooting Checking and acknowledging faults (cont.) Weath. comp. X System Cause characteristics Burner Differential presblocked sure sensor faulty F8 X X Burner in fault state Fuel valve closes too late F9 X X Burner in fault state Fan speed too low at burner start FA X X Burner in fault state Fan speed too high at burner start Fd X X Burner blocked Burner control unit fault 82 Remedy Check the differential pressure sensor and lead. Check gas combination valve.
Troubleshooting Checking and acknowledging faults (cont.) Fault code Const. in the display FE X Weath. comp. X FF X 5692 548 GB X System Cause Remedy characteristics Burner Strong interference Remove EMC blocked (EMC) field nearby; interference. alternatively boiler If the equipment will not coding card or restart, check main PCB faulty the boiler coding card and replace, or replace the control unit. Burner Internal error Remove EMC blocked interference.
Troubleshooting Repairs Checking the outside temperature sensor (weather-compensated control unit) 1. Pull plug X3 from the control unit. 2. Test the resistance of the outside temperature sensor across terminals X3.1 and X3.2 on the pulled plug and compare with the curve. 3. Where actual values strongly deviate from the curve values, disconnect the wires at the sensor and repeat test directly at the sensor. 5692 548 GB 4. Depending on the result, replace cable or outside temperature sensor.
Troubleshooting Repairs (cont.) Check the boiler temperature sensor, cylinder temperature sensor or the flow temperature sensor for low loss header 5692 548 GB 1. Boiler temperature sensor: Pull the leads from boiler temperature sensor A and measure the resistance. Cylinder temperature sensor: Pull the plug % from the cable harness on the control unit and measure the resistance. Flow temperature sensor: Pull plug X3 from the control unit and measure the resistance across terminals X3.4 and X3.5.
Troubleshooting Repairs (cont.) 2. Check the sensor resistance and compare actual values with the curve. 3. Replace the sensor in case of severe deviation. Danger The boiler temperature sensor is immersed in the heating water (risk of scalding). Drain the boiler before replacing the sensor. Checking loading temperature sensor 1. Pull the cables off loading temperature sensor A. 5692 548 GB 2. Check the sensor resistance and compare actual values with the curve.
Troubleshooting Repairs (cont.) 3. Replace the sensor in case of severe deviation. Danger The loading temperature sensor is immersed in the heating water (risk of scalding). Drain the boiler before replacing the sensor. Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler when the permissible flue gas temperature is exceeded. The lockout can be reset no sooner than after 20 minutes by pressing reset E.
Troubleshooting Repairs (cont.) 1. Pull the leads from the flue gas temperature sensor A . 2. Check the sensor resistance and compare actual values with the curve. 5692 548 GB 3. Replace the sensor in case of severe deviation.
Troubleshooting Repairs (cont.) Checking plate heat exchanger 1. Shut off and drain the boiler on the primary and the secondary side. 2. Release the side closures and pivot the control unit forward. 5. Check the secondary side for scaling and, if necessary, replace the plate heat exchanger. 3. Remove the siphon. 6. Check the primary connections for contamination and, if necessary, replace the plate heat exchanger. 4. Release fittings A, screws B and pull plate heat exchanger C forward. 7.
Troubleshooting Repairs (cont.) Checking the thermocouple If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 90 °C: & Pull the leads from thermocouple A. & Check the continuity of the thermocouple with a multimeter. & Remove the faulty thermocouple. & Install a new thermocouple. & After commissioning, press reset button E on the control unit.
Troubleshooting Repairs (cont.) Checking O-rings: 1. Pull off the electrical plug A. 2. Remove sensor B by pulling it upwards. 3. Ensure that both O-ringsC are properly inserted into aperture adaptor retainers D. 4. Insert the sensor with connection nipples into the gas combination valve adaptor and push in until it clicks into place. 5692 548 GB 5. Reconnect the electrical plug-in connector on the sensor.
Troubleshooting Repairs (cont.) Checking the fuse 3. Remove cover A. 2. Release the lateral closures and pivot the control unit down. 4. Check fuse F1. 5692 548 GB 1. Switch OFF the mains power.
Troubleshooting Repairs (cont.) Extension kit for heating circuit with mixer Checking the rotational direction of the mixer motor 1. Switch OFF the motor and restart it at the main ON/OFF switch. The device will carry out the following self-test: & Mixer close (150 seconds) & Pump ON (10 seconds) & Mixer open (10 seconds) & Mixer close (10 seconds) Then standard control mode recommences. 2. Note the rotational direction of the mixer motor during the self-test.
Troubleshooting Repairs (cont.) Checking Vitotronic 050 (accessory) 5692 548 GB Vitotronic 050 is connected with the control unit via the LON system. To test the connection, implement a user check on the boiler control unit (see page 33).
Function description Constant temperature control unit Heating mode The set boiler water temperature will be maintained in the Central heating and DHW heating G program, when a demand is raised by the room temperature-dependent clock thermostat. If no demand is received, the boiler water temperature will be held at the defaulted frost protection temperature.
Function description Constant temperature control unit (cont.
Function description Weather-compensated control unit Heating mode The control unit determines a set boiler water temperature subject to outside temperature or room temperature (if a room temperature-dependent remote control is connected) and the slope/level of the heating curve. The determined set boiler water temperature is then transferred to the burner control unit.
Function description Weather-compensated control unit (cont.
Function description Internal extension H1 Internal extension H1 An external safety valve can be connected to connection gD. 5692 548 GB The internal extension is integrated into the control unit housing. The cylinder loading pump is connected to the relay output sK.
Function description Extensions for external connections (accessory) Internal extension H2 Set coding address 53 to 3. An interlock for extractors can be connected to connection aBJ. 5692 548 GB The internal extension is integrated into the control unit housing. The cylinder loading pump is connected to relay output sK.
Function description Extensions for external connections (accessory) (cont.) External extension H1 aVD & External blocking (terminals 2 - 3) & External demand (terminals 1 - 2) & External operating mode changeover (terminals 1 - 2) aVF External set value 0 to 10 V aVG KM BUS The allocation of function External changeover of operating mode is selected via coding address 91. 5692 548 GB The external extension is connected to the boiler control unit via the KM BUS.
Function description Extensions for external connections (accessory) (cont.) External extension H2 aVD & External blocking (terminals 2 - 3) & External demand (terminals 1 - 2) & External operating mode changeover (terminals 1 - 2) aVG KM BUS The allocation of function External changeover of operating mode is selected via coding address 91. 5692 548 GB The external extension is connected to the boiler control unit via the KM BUS.
Function description Control functions External operating mode changeover The function External operating mode changeover is connected via input aVD of the external extension.
Function description Control functions (cont.) The changeover of operating mode remains active as long as the contact remains closed, but no less than the default duration selected with coding address F2. External blocking The function External blocking is connected via input aVD of the external extension. In coding address 32 you can select the influence the signal Ext. blocking should have on the connected circulation pumps.
Function description Control functions (cont.) Filling program Note Close the gas shut-off valve when operating the filling program. In the delivered condition, the diverter valve is set to its central position, enabling the system to be filled completely. After starting the control unit, the diverter valve no longer goes into its central position. The diverter valve can be moved into its central position via coding address 2F:2.
Function description Control functions (cont.
Function description Control functions (cont.
Designs A1 § 108 Main PCB Boiler temperature sensor $ % Cylinder temperature sensor Loading temperature sensor 5692 548 GB Connection and wiring diagrams – internal connections
Designs Connection and wiring diagrams – internal connectio . . . (cont.
Designs A1 A2 110 Main PCB Mains supply unit A3 A4 Optolink Burner control unit 5692 548 GB Connection and wiring diagrams – external connections
Designs Connection and wiring diagrams – external connectio . . . (cont.
Parts lists Parts lists 001 Heat exchanger connection pipe with gaskets 002 Flow pipework 003 DHW connecting pipe 004 DHW connecting pipe 005 Cylinder connecting pipe 006 Return connecting pipe 007 Gas connection flange 008 Stratification loading cylinder 009 Siphon 010 Condensate hose 011 Heat exchanger siphon connection 012 Heat exchanger 013 Cap plate (with item 014) 014 Profiled gasket 015 Clip nut 016 Interlocking connector 017 Boiler adaptor 018 Plug 019 Air inlet gasket Ø 125 020 Lip seal Ø 80 021
Parts lists Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Parts lists 5692 548 GB Parts lists (cont.
Commissioning/service reports Commissioning/service reports Setting and test values Static pressure Set value Date: By: mbar Supply pressure (flow pressure) = for natural gas E mbar = for natural gas LL mbar = for LPG mbar Initial start-up max. 57.5 mbar 17.4 to 57.5 mbar 17.4 to 57.5 mbar 42.5 to 57.5 mbar Tick gas type Carbon dioxide content CO2 & at lower rated output & at upper rated output Oxygen content O 2 & at lower rated output & at upper rated output % by vol. % by vol. % by vol.
Commissioning/service reports Commissioning/service reports (cont.
Commissioning/service reports Commissioning/service reports (cont.) Setting and test values Static pressure Set value Date: By: mbar Supply pressure (flow pressure) = for natural gas E mbar = for natural gas LL mbar = for LPG mbar Maintenance/ service max. 57.5 mbar 17.4 to 57.5 mbar 17.4 to 57.5 mbar 42.5 to 57.5 mbar Tick gas type Carbon dioxide content CO2 & at lower rated output & at upper rated output Oxygen content O 2 & at lower rated output & at upper rated output % by vol. % by vol.
Commissioning/service reports Commissioning/service reports (cont.
Commissioning/service reports Commissioning/service reports (cont.) Setting and test values Static pressure Set value Date: By: mbar Supply pressure (flow pressure) = for natural gas E mbar = for natural gas LL mbar = for LPG mbar Maintenance/ service max. 57.5 mbar 17.4 to 57.5 mbar 17.4 to 57.5 mbar 42.5 to 57.5 mbar Tick gas type Carbon dioxide content CO2 & at lower rated output & at upper rated output Oxygen content O 2 & at lower rated output & at upper rated output % by vol. % by vol.
Commissioning/service reports Commissioning/service reports (cont.
Specification Specification 230 V~ 50 Hz 6.3 A~ I IP X 4 D to EN 60529 Permissible ambient temperature & in operation: 0 to +40 °C & during storage -20 to +65 °C and transport: Electronic temperature limiter setting: Temperature limiter setting: Mains fuse: 100 °C (fixed) Max. 16 A Power consumption & Circulation pump: & Burner: & Control unit: Gas fired boiler, category II 2ELL3P Rated output TV/T R 50/30 °C Rated output range Connection values * 1 Relative to the max.
Certificates Declaration of conformity Declaration of conformity for Vitodens 333 We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitodens 333 conforms to the following standards: DIN 4702–6 DIN 4753 EN 297 EN 483 EN 625 EN 677 EN 50 165 EN 60 335 EN 61 000-3-2 EN 61 000-3-3 This product is designated in accordance with the following directives: 90/396/EEC 89/336/EEC 73/23/EEC 92/42/EEC 97/23/EC as follows: _-0085 EC Declaration of conformity by an
Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm that the following product meets the NO x limits specified by 1st BImSchV Paragraph 7 (2) [Germany]: Vitodens 333 Allendorf, 14.01.04 Viessmann Werk GmbH&Co KG 5692 548 GB pp.
Keyword index Keyword index A Adjusting the room temperature . . . . 35 B Boiler temperature sensor . . . . . . . . . . . . . Brief scans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner gauze assembly . . . . . . . . . . . . . . . . Burner installation . . . . . . . . . . . . . . . . . . . . . . . . Burner removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 63 20 22 19 C Checking the anode . . . . . . . . . . . . . . . . . . . . .
Keyword index Keyword index (cont.) O Operating mode changeover . . . . . . . 103 Outside temperature sensor . . . . . . . . . . 84 P Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Plate heat exchanger . . . . . . . . . . . . . . . . . . . 89 Product characteristics . . . . . . . . . . . . . . . 126 Protective anode & Checking the anode . . . . . . . . . . . . . . . . . . . 23 R Relay test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692 548 GB
Viessmann Limited Hortonwood 30, Telford, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 www.viessmann.co.uk 132 chlorine-free bleached paper Printed on environmentally-friendly, Subject to technical modifications Compact gas fired condensing boiler Type WS3A 6.6 to 26 kW from serial no.
