KOB PYROT KRT 150 Troubleshooting guide

KRT 150 to KPT 1250
Wood Fired Boiler
Heating output: 150 to 540 kW / 512 to 1843 MBH
Min operation output: 45 to 140 kW / 154 to 478 MBH
Operation and Maintenance Instructions
KÖB IS A ART OF THE VIESSMANN GROU .
yrot oi/ mi 11/2008
Do not store or use gasoline or other lammable
uids in the vicinity o this or any other appliance.
WHAT TO DO IF YOU SMELL FLUE GAS
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 Deactivate heating equipment
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 Open windows and doors.
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 In orm your heating contractor
Installation and service must be per ormed by a
installer or service agency
I the in ormation in this manual is not ollowed
exactly, a ire o r explosion may result causing
property damage, personal injury or loss o li e.
WARNING
Improper installation, adjustment, and/or
operation
could cau se carbon monoxide poisoning
resulting
in injury or loss o li e.
This product must be installed and serviced by
am
pro essional s ervice technician who i s
experienc
ed
IMPORTANT
Read and save these instructions
For uture re erence.
WARNING
PYROT

2
Sa ety, Installation and Warranty Requirements
lease ensure that these instructions are read and understood before commencing installation. Failure to comply
with the instructions listed be low and detail sprinted in t hi s manual can cause product / property / damage,
severe personal injury’, and / or loss of life. Ensure all requirements be low are understood and fulfilled (including
detailed information found in manual subsections).
 Licensed’ pro essional’ heating
contractor
The installation, adjustment,
service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
" Please see section
entitled “Important
Regulatory and
Installation
Requirements”.
 Product documentation
Read all applicable documentation
before commencing installation.
Store
documentation near boiler in a
readily
accessible location for reference in
the future by service personnel.
" For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and Safety
Requirements”.
 Advice to owner
Once the installation work is
complete, the heating contractor
must
familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-
down
procedure, and the need for
professional service annually before
the heating season begins.
 Contaminated air
Air contaminated by chemicals can
cause by-products in the
combustion
process which are poisonous to
inhabitants and destructive to
Viessmann equipment.
" For a listing of
chemicals which cannot
be stored in or near the
boiler room, please see
subsection entitled
“ ombustion air supply”.
 Carbon monoxide
Improper installation, adjustment,
service and/or maintenance can
cause
flue products to flow into living
space.
Flue products contain poisonous
carbon monoxide gas.
" For information
pertaining to the proper
installation, adjustment,
service and maintenance
of this equipment to
avoid formation of carbon
monoxide,
please see instructions supplied with
burner.
 Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
" For information
pertaining to the fresh
air requirements of this
product, please see
subsection entitled
“ ombustion air supply”.
 Equipment venting
Never operate boiler without an
installed venting system. An
improper
venting system can cause carbon
monoxide poisoning.
" For information
pertaining to venting
and chimney
requirements, please
see section entitled “Venting
onnection”. All products of
combustion must be safely vented
to
the outdoors.
 Warranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.

3
Sa ety, Installation and Warranty Requirement
 Fiberglass wool and ceramic iber
Materials
The state of California has listed the
airborne fibers of these materials as
a
possible cancer hazard through
inhalation. When handling these
materials, special care must be
applied.
Suppliers of ceramic fiber products
recommend the following first aid
measures:
- Respiratory tract (nose and throat)
irritation
If respiratory tract irritation
develops,
move the person to a dust free
location.
- Eye irritation
If eyes become irritated, flush
immediately with large amounts of
lukewarm water for at least 15
minutes. Eyelids should be held
away
from the eyeball to ensure thorough
insing. Do not rub eyes.
- Skin irritation
If skin becomes irritated, remove
soiled clothing. Do not rub or
scratch
exposed skin. Wash area of contact
thoroughly with soap and water.
Using a skin cream or lotion after
washing may be helpful.
- Gastrointestinal irritation
If gastrointestinal tract irritation
develops, move the person to a dust
free environment.
Suppliers of fiberglass wool
products
recommend the following
precautions
be taken when handling these
materials:
Precautionary measures
- Avoid breathing fiberglass dust
and
contact with skin and eyes.
- Use NIOSH approved dust/mist
respirator.
- Wear long-sleeved, loose fitting
clothing, gloves and eye protection.
- Wash work clothes separately
from
other clothing. Rinse washer
thoroughly.
- Operations such as sawing,
blowing,
tearout and spraying may generate
airborne fiber concentration
requiring
additional protection.
First aid measures
- If eye contact occurs, flush eyes
with
water to remove dust. If symptoms
persist, seek medical attention.
- If skin contact occurs, wash
affected
areas gently with soap and warm
water after handling
 Hazardous materials

4
Sa ety, Installation and Warranty Requirement

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Take note of all symbols and notations intended to draw attention to potential hazards or important
product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below im
portant product information.
 Warnings draw your
attention to the
presence of potential
hazards or
information.
 Cautions draw your
attention to the
presence of potential
hazards or
important product
information.
 Helpful hints for Installation,
operation or maintenance
which pertain to the product.
 This symbol indicates that addi-
tional, pertinent Information is
to be found in the adjacent
column
 This symbol indicates that
other instructions must be refer-
enced.


5
Contents
1 General In ormation________________________________________________________7
1. Sa tey Requirements ____________________________________________________________________7
1.1 Foreword_____________________________________________________________________________ 11
1.2 Technical standing _____________________________________________________________________ 11
1.3 Intended use __________________________________________________________________________ 11
1.4 Technical data_________________________________________________________________________ 11
1.5 In ormation documented________________________________________________________________ 11
1.6 CSA and ASME certification _________________________________________________________ 11
2Important Information _____________________________________________________________12
2.1 Sa ety instructions_____________________________________________________________________ 12
2.2 Excess temperature/power ailure _______________________________________________________ 12
2.3 Low water/excess water pressure _______________________________________________________ 12
2.4 A ire hazard __________________________________________________________________________ 13
2.5 Wood uels, minimum requirements _____________________________________________________ 13
2.6 Filling the uel storage unit______________________________________________________________ 13
2.6.1 By dumping ___________________________________________________________________________ 13
2.6.2 By blowing in__________________________________________________________________________ 13
2.7 Correcting mal unctions in the eed systems _____________________________________________ 13
3 How the Boiler Plant is Strucured _________________________________________ 14
4 Commissioning/Operation ________________________________________________ 15
4.1 The initial start-up _____________________________________________________________________ 15
4.2 Operation _____________________________________________________________________________ 15
4.2.1 Heating up ____________________________________________________________________________ 15
4.2.2 Operation _____________________________________________________________________________ 15
4.2.3 Switching off _____________________________________________________________________15
5 The ECOTRONIC control system__________________________________________ 16
5.1 General in ormation ____________________________________________________________________ 16
5.1.1 Replacing the battery __________________________________________________________________ 16
5.2 The unctions o the keys ______________________________________________________________ 16
5.3 Boiler and loader system (F3/F4) ________________________________________________________ 17
5.3.1 The F3 KEY: " YROT arameters" ______________________________________________________ 17
5.3.2 The F4 KEY: " YROT Loader System" ___________________________________________________ 18
5.4 Extended control systems F5 – F8 (optional) _____________________________________________ 19
5.4.1 Room heating system __________________________________________________________________ 19
5.4.2 Utility water heater ____________________________________________________________________ 21
5.4.3 Air heater _____________________________________________________________________________ 22
5.4.4 Annex buildings _______________________________________________________________________ 23
5.4.5 ipelining _____________________________________________________________________________ 24
5.4.6 Additional heat generator_______________________________________________________________ 25
5.4.7 Solar__________________________________________________________________________________ 26

6
6 Cleaning/Maintenance ___________________________________________________ 27
6.1 Boiler _________________________________________________________________________________ 27
6.2 Installing the displacement rods into the heat exchanger __________________________________ 29
6.3 Feed systems__________________________________________________________________________ 30
7 Shutdown ______________________________________________________________ 30
8 Carrying out disposals ___________________________________________________ 30

7
1 General In ormation
1.1 Important Regulatory and Sa ety Requirements
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 Operation
Before operating the boiler, make sure you fully un-
derstand its method of operation. Your heating con-
tractor should always perform the initial start-up and
explain the system. Any warranty is null and void if
these instructions are not followed.
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 Working on the equipment
All personnel working on the equipment or the heat-
ing system must have the proper quali ications and
hold all necessary licenses.
Ensure main power to equipment, heating system,
and all external controls has been deactivated. Close
main oil or gas shut-o valve. Take precautions in
all instances to avoid accidental activation of power
during
service work.
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 Dangerous conditions
– Deactivate main power immediately.
– Close main gas or oil shut-off valve.
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 Flue gas smell
– Deactivate heating equipment.
– Open windows and doors.
– Inform your heating contractor.
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 Combustion air and ventilation air openings
Ensure that combustion air openings and ventilation
air openings in the mechanical room are open.
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 Technical in ormation
Literature applicable to the YROT:
– Installation Instructions
– Operating Instructions
Keep all literature in a sa e place at the installation
site. Contact Viessmann or additional copies.
Incomplete combustion and
)
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 Regular maintenance and service
The entire heating system must be cleaned and ser-
viced on a regular basis by a qualified heating
contractor or service agency to ensure reliable,
energy-efficient, and environmentally
friendly operation.
The build-up of soot on the heat exchanger raises
the flue gas temperature and reduces efficiency.
Indirect-fired domestic hot waterstorage tanks (if in-
stalled) must be serviced within two years (at most)
of the installation date, and regularly thereafter (see
Service Schedule starting).
For an overview of scheduled service procedures,
please see section entitled “Service Schedule”.

8
Keep boiler and boiler room clear and ree rom
combustible materials, gasoline and other lammable
vapors and liquids. Do not obstruct the low o
combustion and ventilation air. A quali ied heating
contractor must per orm all inspection, maintenance
and service.
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 Important to know
Do not use this boiler if any part has been under, or
exposed to, water. Immediately call a qualified heat-
ing contractor to inspect the boiler and to replace
any part of the control
system and any gas control which has been under,
or exposed to water.
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 Carbon monoxide
The U.S. Consumer roduct Safety
Commission strongly recommends the installation of
carbon monoxide detectors in buildings in which
gas-burning equipment is installed.
Carbon monoxide (CO) is a colorless, odorless gas,
which may be produced during incomplete combus-
tion of fuel and/or when the flame does not receive
an adequate supply of combustion air.
Carbon monoxide can cause severe personal injury
or loss of life.
Therefore, carbon monoxide detectors that are in
compliance with a nationally recognized standard
(e.g. ANSI/UL 2034-2002, CSA 6.19-01) should be
installed and maintained in buildings that contain
gas-burning equipment.
Note:
Viessmann does not test any detectors and makes
no representation regarding any brand or type of de-
tector.
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 For sa e operation
We recommend that you frequently:
- Check for debris which could obstruct the flow of
flue gases. The vent or chimney must not be
blocked. Ablocked or partially blocked vent or chim-
ney can cause flue gases to leak
into the structure. Flue gases leaking into the house
can cause injury or death. Blocked or partially
blocked chimneys must have the blockage removed
by a qualified heating contractor.
- Check pressure gage for correct system (water)
pressure. Check for water on the floor from the dis-
charge pipe of the pressure relief valve or any other
pipe, pipe joint, valve or air
vent.
- Check for moisture, water, or appearance of rust
on the flue gas pipes, their joints as well as vent
dampers, or side wall vent terminals
(if so equipped).
- Ensure that nothing is obstructing the flow of
combustion and ventilation air and no chemicals,
garbage, gasoline, combustible materials, flammable
vapors and liquids are stored (not even temporarily)
in the vicinity of the boiler.
- Do not allow unsupervised children near the boiler.
Service/inspection of the boiler and the system is
recommended once a year. Maintenance, service
and cleaning are specified in the Installation Instruc-
tions.

9
a ety (continued)
Frozen water pipe hazard
Your heating boiler is designed to provide
a warm and comfortable living environment. It is
NOT designed to ensure against freezing of water
pipes. The boiler is equipped with several safety de-
vices that are designed to shut down the boiler and
to prevent it from
restarting in the event of various unsafe
conditions.
If your boiler remains off for an extended period of
time during cold weather, water pipes may freeze
and burst, resulting in extensive water damage and
conditions in which mold could grow. Certain molds
are known to cause respiratory problems, as well as
to pose other serious health risks. In case of water
damage, immediate measures should be taken to dry
out affected areas as quickly as possible to prevent
mold from developing.
If your home will be unattended for anextended pe-
riod of time during cold weather, you should...
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 Shut off the water supply to the building, drain
the water pipes and add antifreeze for potable water
to drain traps and toilet tanks. Open faucets where
appropriate.
Or…
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 Have someone check the building frequently dur-
ing cold weather and call a qualified service agency
if required.
Or...
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 Install a reliable remote temperature sensor that
will notify somebody offreezing conditions within
the home.
Failure to protect against rozen pipesa ety
I you notice ire coming rom the appliance, call the
ire department immediately! Do not attempt to ex-
tinguish the ire unless quali ied to do so.
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 Installation area conditions
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 Ensure ambient temperatures are higher than
50°F / 10°C and lower than 104°F / 40°C.
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 revent the air from becoming contaminated by
homogenate hydrocarbons (e.g. as contained in
paints solvents or cleaning fluids) and excessive
dust (e.g. through grinding or polishing work).
Combustion air for the heating process, and ventila-
tion of the boiler room must be free of corrosive
contaminants. To that end, any boiler must be in-
stalled in an area that has no chemical exposure.
The list to the right indicates the main, currently
known sources.
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 Avoid continuously high levels of humidity (e.g.
through frequent drying of laundry).
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 Never close existing ventilationopenings.
Replacement components, spare and wear parts.