Viessmann Vitomax LW Series Training manual

Operating and service instructions
for contractors
Viesmann
Vitomax LW
Type M148
Type M62
Type M64
Type M82
Type M84
Low pressure hot water boilers
VITOMAX LW
5673144 GB 1/2019 Please keep safe.

2
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 intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■Pressure Equipment Directive
■Gas Appliances Regulation
■German Operational Safety Ordinance (BetrSichV)
and extended technical rules for operational safety
(TRBS)
■Country-specific safety regulations for the installation
site
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
Safety instructions for working on the system
Commissioning
Note
Unpleasant odours may develop during commission-
ing. Ensure the installation room is well ventilated.
Before working on the system
■Close the fuel shut-off valve and secure against
unintentional reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
Hot surfaces
Danger
Hot surfaces can cause burns. Never touch hot
surfaces, e.g.
■Steam pipes
■Hot water pipes
■Cleaning apertures and closures on the boiler
system
■Boiler doors, as well as components behind
the doors
Observe occupational safety. Wear protective
clothing where necessary.
Electrostatic discharge
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Safety instructions
Safety instructions
5673144

3
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Dismantling and disposal
When dismantling and disposing of thermal insulation
materials and gaskets/seals on the gas side, observe
the applicable safety regulations.
The product and its components must be disposed of
according to local environmental regulations.
This applies in particular to the disposal of thermal
insulation materials and gaskets/seals on the gas side.
Safety instructions for operating the system
General
The materials included in the product pose no threat to
health during operation.
If you notice oil leaks or smell gas
Danger
Escaping fuel can lead to explosions which may
result in very serious injuries.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the quick-acting fuel valve and shut-off
valve.
■Ventilate the boiler house.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the system.
■Ventilate the installation site.
Draining hot water
!Please note
The blow-down and TDS water from boiler sys-
tems can reach temperatures of over 100 °C.
Before draining water into the sewage system,
allow it to cool to a temperature of < 35 °C. If
necessary, consult the local water board.
Draining condensate from the flue gas side
!Please note
When starting up the boiler system, or under
certain operating conditions, condensate may
build up in the flue passes, the flue gas collector
and the downstream flues, including the chim-
ney.
The condensate must be drained away safely by
means of suitable installation measures put in
place by the system installer.
Subject to the regulations in the country concerned,
this condensate may need to be neutralised. In such
cases, consult the local water board or the body
responsible for issuing permits.
General information
Shut down the boiler immediately if there is any
safety-related damage.
Observe safety-related instructions.
After an accident, the condition of the system must not
be changed before the investigation takes place,
unless necessary in order to rescue people or prevent
further damage.
Safety instructions
Safety instructions (cont.)
5673144

4
Only authorised personnel are permitted to enter the
boiler house.
Keep the boiler house clean at all times.
Do not store anything in the boiler house.
Keep exits clear.
Never use the boiler house or system components as
a drying area.
The operating personnel must log the following:
■Settings
■Readings
■Faults
■Replacement of spare parts
■Repairs
Any defects must be dealt with immediately by trained
personnel, e.g.:
■Abnormalities on weld seams
■Leaks
■Heavy corrosion
■Faulty instrument displays
■Noise in the boiler
Faults and defects that cannot be remedied locally
must be reported to the manufacturer. Protect all boiler
parts and control equipment from rain, water leaks and
expelled steam.
Safety instructions
Safety instructions (cont.)
5673144

5
1. Information Symbols ................................................................................................. 6
Note ....................................................................................................... 6
Designation of boiler types .................................................................... 6
Intended use .......................................................................................... 7
2. Operating information Operating tips ........................................................................................ 8
■Required water properties .................................................................. 8
■Commissioning ................................................................................... 8
■Systems with operating temperatures > 110 °C .................................. 8
Shutdown and preservation ................................................................... 8
■Shutdown ............................................................................................ 8
■Brief interruption in operation ≤ 3 days ............................................... 9
■Interruption in operation > 3 days ....................................................... 9
■Treating the flue gas side ................................................................... 10
Information on maintenance .................................................................. 10
■Preventing excessive flue gas temperatures ...................................... 11
Standard values for water quality .......................................................... 11
■Flow temperatures ≤ 100 °C (VDI 2035 Part 1-2) ............................... 11
■Flow temperatures > 100 °C (VdTÜV MB 1466) ................................ 12
■Preventing water side corrosion ......................................................... 13
3. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 14
4. Wearing parts Wearing parts and gaskets .................................................................... 29
■Viessmann Industrial Service contact details ..................................... 32
5. Commissioning/service
reports
Reports for commissioning, inspection and maintenance ..................... 33
6. Keyword index ................................................................................................................ 34
Index
Index
5673144

6
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Note
All diagrams in this document are schematic, illustra-
tive examples.
Designation of boiler types
Capital letters indicate the respective stage of develop-
ment (version) of the boiler type.
Example M62C: Boiler type M62 version C
Information
Symbols
5673144
Information

7
The appliance is intended solely for installation and
operation in sealed unvented heating systems, with
due attention paid to the associated installation, serv-
ice and operating instructions. The appliance is inten-
ded exclusively for steam generation and for heating
water in accordance with EN 12953 and AGFW data-
sheet FW510 (VdTÜV datasheet TCh 1466).
Commercial or industrial use for a purpose other than
steam generation or the heating of water shall be
deemed inappropriate.
All other use is deemed inappropriate. Any resulting
losses are excluded from the manufacturer's liability.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Intended use presupposes that a permanent installa-
tion in conjunction with permissible components
designed for this purpose has been carried out.
Intended use also includes adherence to maintenance
and inspection intervals.
Information
Intended use
5673144
Information

8
Required water properties
The required water properties for the operation of
boiler and heating systems are specified in the "Stand-
ard values for water quality" chapter on page 11.
Commissioning
Note
Ensure that the installation room is well ventilated dur-
ing commissioning as there may be some odour nui-
sance.
Authorised to commission the boiler:
■Viessmann Industrial Service (for contact details see
page 32) or
■The system installer or
■An approved contractor or institution nominated by
the system installer
Required for commissioning:
■Presence of a competent expert authority
■Completion of a test report
■Required signatories:
–System builder
–Regulatory expert
–System user
■The flue gas inspector (where applicable) should be
notified of the commissioning within 4 weeks
Recommended operating conditions to prevent
damage to the boiler system
Never interrupt boiler operation, even if no heat is
being drawn off temporarily
Maintain the following at all times
■Water temperature: 70 °C
■Specified operating pressure
Multi boiler systems with a boiler on permanent
standby:
Changeovers between heating and standby should be
infrequent, for example with each annual inspection of
the overall system.
Systems with operating temperatures > 110 °C
Category IV boiler systems compliant with Pressure Equipment Directive
Requirements for commissioning
■System installation has official approval.
■The system has been checked by an expert author-
ity.
■Commissioning of the control system is carried out
by a qualified organisation.
Requirements for operators
Only qualified personnel may operate, supervise and
service the system.
Requirements for operation without supervision
■Boiler system is equipped in accordance with EN
12953, Part 6.
■The system has received official approval for opera-
tion.
Checking system operation
Scope checks should be determined in accordance
with EN 12953-6
Shutdown and preservation
Shutdown
Shutdown means shutting down the system via the cir-
cuit breaker at the control panel. The duration of the
shutdown determines the preservation measures
described in this chapter.
A short-term shutdown is not recommended, as every
start-up process subjects the boiler to additional
stresses. For a period of up to 72 hours, for example
over a weekend, the boiler should be left to continue
operating.
Operating information
Operating tips
5673144
Operation

9
What preservation is for
A depressurised boiler system is at risk from idle-time
corrosion. Preservation measures prevent such corro-
sion.
Preservation measures are carried out on flue gas side
and water side surfaces of a boiler system. The type of
preservation depends on the type and duration of the
interruption in operation.
Type of preser-
vation
Effect
Wet preservation Keeps oxygen away from the boiler
system.
Dry preservation Keeps moisture in the boiler system
to a minimum.
Tab. 1
Interruption in operation
Duration Recommendation
≤ 3 days Maintain the positive pressure in the boil-
er system incl. all boiler-related equip-
ment (thermal water treatment, etc.).
> 3 days Select type of preservation.
Tab. 2
Basic rule
VdTÜV datasheet TC 1465 "Preserving the water side
of steam boilers"
Recommendation
If using preservation methods that include chemicals
other than those stated here, please consult the manu-
facturers of the chemicals.
Brief interruption in operation ≤ 3 days
Treatment for preservation of the water side
Operating
condition
Measures
The boiler is
switched off.
Add oxygen binder to the feedwater 1
hour before switching off. Dosing: 2
to 3 times the standard dose
The boiler re-
mains on.
Maintain the boiler system pressure
and temperature.
Tab. 3
Preserving agents: Ammonia or nitrogen
■A technically demanding form of preservation.
■Consult the chemical manufacturer before use.
■The operator must compile system-specific operating
instructions.
Treating the flue gas side
■Keep heating surfaces dry.
■Remove severe contamination as it binds moisture.
Interruption in operation > 3 days
Treatment for preservation of the water side
Dry preservation
Note
The system cannot be restarted quickly.
Applications:
■Prolonged boiler idle periods
■Risk of frost
See the "Using antifreeze in boilers" chapter in
the technical guide
Application:
1. Drain hot water boilers at < 90 °C.
!Please note
Draining hot water into the sewage system
causes environmental damage.
Cool the water to < 35 °C beforehand. If
necessary, collect it in containers.
2. Open the water closures.
3. Dry the boiler system thoroughly.
4. Place desiccant (silica gel) in the boiler system in
accordance with the manufacturer's instructions.
Note
Ensure that the desiccant does not come into
direct contact with the boiler material.
5. Close the boiler system.
6. Check the effectiveness of the desiccant regularly.
Wet preservation
1. Fill the boiler system up to the highest possible
level with treated feedwater.
2. Mix oxygen binder, e.g. sodium sulphite, into the
boiler water in accordance with the manufacturer's
instructions. Mix it thoroughly with the boiler water
by means of thermal or mechanical circulation.
Oxygen binder inhibits oxygen corrosion.
Operating information
Shutdown and preservation (cont.)
5673144
Operation

10
3. Check the concentration of the oxygen binder reg-
ularly and at least every month; if necessary, add
more oxygen binder.
Preserving single boilers in a multi boiler system
The temperature of the relevant boilers is maintained
by letting boiler water from the remaining boiler system
flow through them.
Corrosion protection in a filled boiler shell
A fully filled boiler shell is maintained at a pressure of
0.1 to 0.2 bar using nitrogen, specifically nitrogen 5.0.
!Please note
Frost may cause damage to the boiler.
Do not use wet preservation if there is a risk of
frost!
!Please note
Do not use layer-forming monoamines.
The use of film-forming polyamines must be
agreed with and approved by the boiler manu-
facturer.
Recommendation
Agree the steps for the preservation of the water side
with the manufacturer of the preserving agent.
Applicable regulations
Draining preserving solutions
■Conditions for draining waste water into sewer sys-
tems or the main discharge system
Use of preserving agents
■Working instructions and safety datasheets supplied
by the product manufacturer
Treating the flue gas side
1. Clean the heating surfaces on the flue gas side.
Maintain the alkaline balance of the water used for
cleaning at pH 8 to 9, or, in the case of ammonia,
pH 10.
2. Dry the heating surfaces on the flue gas side (allow
normal air flow).
3. Accelerate the ventilation process by means of a
fan heater. If necessary, open the flue gas shut-off
dampers, then close them again.
4. Spray preserving oil, e.g. graphite or varnish, onto
the combustion chamber walls and hot gas flues,
or apply it with a brush.
5. Keep the boiler door(s) open. Keep the boiler sur-
faces dry during idle periods.
6. Employ a desiccant (silica gel).
7. Use a dryer with a fan.
Recommendation for areas with high relative
humidity
Do not use dry preservation in areas with high relative
humidity (in the tropics, near the sea) due to the spe-
cial installation conditions that prevail in these areas.
Detailed information
■Operating instructions for preservation on the
water and hot gas side
■Datasheets of the VdTÜV, no. MB TECH
1466, dated 2014-01, and the VGB,
no. R116H, dated 2009
Information on maintenance
Correct maintenance ensures trouble-free, efficient
and environmentally responsible system operation:
■Observe the specified maintenance intervals
■Only use authorised companies:
–Viessmann Industrial Service (for contact details
see page 32)
–Other authorised contractors
Operating information
Shutdown and preservation (cont.)
5673144
Operation

11
Preventing excessive flue gas temperatures
Excessively high flue gas temperatures make the
system less efficient
Cause of fault Remedy
Altered burner
setting
Adjust the burner correctly
Contaminated
boiler system
Clean the boiler system
Tab. 4
Recommendation
Continuous monitoring of the flue gas temperature
using a flue gas thermometer
Standard values for water quality
Advantages of complying with the guidelines
■Prolonged boiler service life
■Reduced repair costs
Advantages of using chemical water treatment
■The specified standard values and water conditions
are observed
■No additional corrosion protection is required
–if the system is designed as a hot water heating
system sealed against corrosion and
–if all the other instructions stated in the "Standard
values for water quality" chapter are complied with
Recommendation
Use chemical water treatment in the boiler system.
Request a quotation from Viessmann (for contact
details see page 32).
Note
Observation of the following requirements is a neces-
sary condition for safeguarding your warranty rights.
The warranty excludes damage caused by scaling or
failure to adhere to water quality conditions.
Flow temperatures ≤ 100 °C (VDI 2035 Part 1-2)
Recommendations
■Prevent scale deposits (calcium carbonate) from
forming on the heating surfaces.
■Pay particular attention to the standard values speci-
fied in VDI Guideline 2035 Part 1 "Prevention of
damage in water heating installations - Scale forma-
tion in domestic hot water supply installations and
water heating installations"
Conditions of applicability
■Fill and top-up water consumed by the system during
its service life: max. 3 times its capacity
■Specific system volume: < 20 l/kW heating output.
For multi boiler systems: The output of the smallest
steam boiler or hot water boiler applies here
■All measures to prevent water side corrosion in
accordance with VDI 2035 Part 2 have been com-
plied with
Standard values (extract)
Total heating output kW > 600
Total alkaline earths mol/m3< 0.02
Total hardness °dH < 0.11
Tab. 5
Fill and top-up water
Soften the water:
■If the total of alkaline earths in the fill and top-up
water exceeds the standard value
■If larger fill and top-up water volumes are expected
Log the water volumes:
■Install a water meter
■Enter the volume of water filled and the water hard-
ness into the system operator's log
Reduction of water consumption:
Install shut-off valves in each section of the system.
This enables the heating water to be drained just
from the affected section when work is required on
the system.
Operating information
■Start the system in stages:
–Begin with the boiler with the smallest output
■Prevent localised limescale deposits on the heating
surfaces by setting a high heating water flow velocity
■When carrying out work on the system, only drain
the affected sections of the system
Operating information
Information on maintenance (cont.)
5673144
Operation

12
■Only fill the heating system with treated water.
Occasions when this will be necessary:
–Commissioning
–Recommissioning
–After repairs or system expansion
–When filling with top-up water
■Check filters, dirt traps and other blow-down or sepa-
rating facilities in the heating water circuit for depos-
its, clean and test their function:
Interval:
–After commissioning and reinstallation: Frequently
–Depending on the water treatment applied, e.g.
water softening: As required
Limescale deposits
Production
Limescale deposits shorten the service life of the
boiler. They form when the specified preventive meas-
ures have not been implemented correctly.
Preventive action:
■Observe VDI Guideline 2035
■Observe the information in these instructions
Remedial measures:
■Remove deposits immediately
■Restore the operational functionality of the boiler
system
■Check the boiler system for damage before recom-
missioning
■Ensure that excessive limescale deposits (scaling)
cannot reoccur
■Rectify incorrect operating parameters
Recommendation
Commission Viessmann Industrial Service (for contact
details see page 32) or another contractor to carry
out the relevant measures.
Flow temperatures > 100 °C (VdTÜV MB 1466)
Operation with circulating water with low salt con-
tent
Note
Only use fill and top-up water with low salt content,
e.g. desalinated water, permeate or condensate.
For systems using mixed condensation:
As a rule, these systems automatically create water
with a low salt content if no boiler water is fed into the
system for alkalisation.
Operation with saline circulating water
Required properties for the fill and top-up water:
■Low salt content
■Free of alkaline earths and softened
Boiler water properties Requirements
Salt content Low salt Saline
Electrical conductivity at 25 °C μS/cm 10 to 30 > 30 to 100 > 100 to 1500
General properties Clear, free of sediment
pH value
■At 25 °C
■In accordance with the Drinking Water Ordi-
nance/Drinking Water Treatment Ordinance
9 - 10 9 - 10.5 9 - 10.5
≤ 9.5 ≤ 9.5 ≤ 9.5
Oxygen (O2)*1 mg/l < 0.1 < 0.05 < 0.02*2
Alkaline earths (Ca, Mg) mmol/l < 0.02 < 0.02 < 0.02
Phosphate
■PO4
mg/l < 5 < 10 < 15
■In accordance with the Drinking Water Ordi-
nance/Drinking Water Treatment Ordinance
mg/l ≤ 7 ≤ 7 ≤ 7
■For Viessmann hot water boilers mg/l < 2.5 < 5 < 15
Use of oxygen binders:
Sodium sulphite (Na2SO3)*3 mg/l – – < 10
Tab. 6
*1 Lower values are possible in continuous operation.
*2 If using permissible inorganic corrosion inhibitors in the circulating water, oxygen concentrations up to 0.1 mg/l are possible
*3 If using other permissible products, follow the respective manufacturer's guidelines.
Operating information
Standard values for water quality (cont.)
5673144
Operation

13
Preventing water side corrosion
General information
Oxygen is introduced into the heating system with the
fill water when the system is filled initially and during
any subsequent top-ups.
This oxygen reacts with materials without causing any
damage to the system.
After a certain time in operation, the water in the sys-
tem turns black because there is no more free oxygen
present in the system.
As there is now no oxygen in the heating water, the
materials of the heating system and boiler are protec-
ted from corrosion on the heating water side.
!Please note
The ingress of oxygen can cause damage as a
consequence of oxygen corrosion.
Prevent the ingress of oxygen by means of suit-
able measures.
Protecting the heating water from oxygen ingress
■Prevent continuous oxygen ingress and the entry of
airborne oxygen into the system during operation.
■Apply technical rules, specifically VDI Guideline
2035-2.
■Ensure that the heating system is designed correctly
(dimensions, system pressure).
■Operate the heating system in line with regulations.
■Equip sealed unvented systems with a diaphragm
expansion vessel or similar.
Recommendation for diaphragm expansion vessel
Check the pre-charge pressure during the annual serv-
ice or sooner.
Pressure maintaining systems and corrosion
See chapter "General design information" in the
technical guide
Operate the system with positive pressure
■In the entire boiler system
■On the pump suction side
■In every system operating state
Only use gas-impermeable components for the
systems.
■If using permeable components, separate the sys-
tems (heat exchangers).
■In permeable components such as underfloor heat-
ing systems, only use impermeable plastic pipes.
■Separate the water flowing through the plastic pipes
from the boiler and other heating circuits with a heat
exchanger made from corrosion-resistant material.
Additional protection against oxygen ingress
■Add an oxygen binder (in excess of 5 - 10 mg
Na2SO3/l).
■Adjust the pH value of the heating water to 8.2 - 9.5.
Use of aluminium components
Note that different conditions may apply.
Corrosion protection with chemicals:
Obtain a safety declaration from the chemical manu-
facturer regarding the interaction of the chemicals with
the materials used in the steam boiler, the hot water
boiler and the other components of the heating sys-
tem.
Recommendation
Consult the relevant contractor regarding water treat-
ment.
Detailed information
VDI Guideline 2035-2 and EN 14868
Operating information
Standard values for water quality (cont.)
5673144
Operation

14
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 15
• • 2. Shutting down the system................................................................................................. 16
•3. Removing the burner (if required).................................................................................... 16
•4. Type M148: Moving the hinge brackets to the other side of the boiler door................ 17
• • 5. Opening the boiler door(s)................................................................................................ 20
• • 6. Removing the closures of the inspection ports.............................................................. 21
•7. Removing and cleaning the turbulators (if installed)..................................................... 21
•8. Cleaning the heating surfaces and flue gas collector.................................................... 21
••• 9. Checking the gaskets and packing cords on the flue gas side
• • 10. Cleaning the sight glass.................................................................................................... 21
••• 11. Checking the thermal insulation components and gaskets........................................... 22
••• 12. Inserting turbulators (if installed) and closing the boiler door(s)................................. 23
••• 13. Closing and securing the inspection ports..................................................................... 24
• • 14. Mounting the burner (if required)..................................................................................... 24
•15. Checking the water chamber for deposits....................................................................... 24
• • 16. Checking the connections and inspection ports on the water side for leaks.............. 24
••• 17. Checking the water level and system pressure
••• 18. Checking the safety and control equipment.................................................................... 25
••• 19. Checking the safety valve................................................................................................. 25
• • 20. Checking the water quality................................................................................................ 25
• • 21. Checking the thermal insulation
••• 22. Checking the installation room ventilation
••• 23. Checking the flue pipe for tightness
• • 24. Adjusting the burner.......................................................................................................... 26
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5673144

15
Information on burners and accessories
01. Check that the fuel being used is permissible for
the current system configuration.
02. Open the boiler door/doors.
03. Insert the turbulators into the hot gas flues as far
as they will go.
04. Close the boiler door(s).
05. Open the installation room vents.
06. Fill the heating system with water and vent the
system.
!Please note
Unsuitable boiler water may damage the
boiler system.
Use the correct water at all times.
See chapter "Standard values for water
quality"
Note
Document the charge and overall water hardness.
07. Check the system pressure.
08. Check all fitted components for function and tight-
ness.
09. Check the fuel supply pressure and tightness.
10. Open the flue gas damper.
11. Close the cleaning aperture on the flue outlet.
12. Check the connection between the drain line and
the condensate connection.
13. Open the shut-off valves in the oil lines at the tank
and filter, or open the gas shut-off valve.
14. Start the system in the following order:
■Mains isolator
■Switches for all the equipment required for oper-
ating the boiler system
■ON/OFF switch for the burner
Operating instructions for the burner
15. Start the system at a low heating output (max.
30 %).
16. Open the condensate drain.
17. Heat up the system to a temperature 20 K below
the operating temperature.
18. Collect and remove the condensate correctly.
19. As soon as the required flow temperature is
reached, open valves in the following sequence:
■Boiler return valve
■Feedwater valve, if required
■Boiler flow valve (open slowly)
20. Close the condensate drain.
21. Enable full burner load.
22. While the system heats up, monitor the following:
■Function of the control and safety equipment
■Pressure and temperature
23. Check the tightness of the covers and retighten if
necessary (see table 7).
24. After approx. 50 hours run, check the tightness of
the following assemblies:
■Boiler door/doors
■Closures for the inspection port (tighten screws
if necessary)
Commissioning, inspection, maintenance
Commissioning the system
5673144

16
Tightening torques Ma*4
Cover Dimensions Ma
Handhole 100 x 150 mm M16 100 Nm
Headhole 220 x 320 mm M20 200 Nm
Manhole 320 x 420 mm M24 350 Nm
Tab. 7
Shutting down the system
Danger
Risk of injury when opening pressurised boiler
flue connections.
Do not open boiler flue connections until they
are depressurised and have cooled down.
!Please note
Draining hot water into the sewage system cau-
ses environmental pollution.
Therefore cool the water to < 35 °C beforehand.
If necessary, collect it in containers.
1. Shut down the burner.
2. Close the shut-off valves in the oil lines (at the tank
and filter) or the gas shut-off valve.
3. Isolate the system from the power supply.
4. Close all valves.
Removing the burner (if required)
A
B
Fig. 1
1. Remove the fuel supply line.
2. Undo screws A and remove the burner with
burner plate B.
!Please note
The flame tube may be damaged if it comes
into contact with the burner or door.
Ensure the burner and burner plate are not
canted on removal.
Use a suitable tool/lifting apparatus.
Installation information "Insulation for burner
entry point", burner installation and service
instructions
*4 Under cold and hot conditions
Commissioning, inspection, maintenance
Commissioning the system (cont.)
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17
Fig. 2
Danger
Risk of injury through falling boiler door.
The hinge brackets may only be moved to the
other side of the boiler door if the burner has
been removed and the boiler door is closed.
1.
Fig. 3
01. Remove top nut and washer.
3.
2.
2.
Fig. 4
02. Remove split pin and pull out bolt.
03. Remove eye screw.
Commissioning, inspection, maintenance
Type M148: Moving the hinge brackets to the other side of the boiler door
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18
4.
7. 8.
5.
Fig. 5
04. Insert eye screw behind joint piece.
05. Screw on the nut and push on the washer.
06. Push eye screw through hole.
07. Mount washer and screw on nut (washer and nut
are supplied with the hinges).
08. Insert bolt.
9.
Fig. 6
09. Tighten nuts (approx. 100 Nm).
Secure bolt with split pin.
10. Repeat steps 1 to 9 for the lower fitting.
11.
12.
Fig. 7
11. Remove split pin and undo nuts.
12. Pull out bolt.
Commissioning, inspection, maintenance
Type M148: Moving the hinge brackets to the… (cont.)
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19
14.
13.
13.
Fig. 8
13. Remove nuts and washers.
14. Remove eye screw.
17.
15.
16.
18.
Fig. 9
15. Insert eye screw.
16. Insert bolt.
17. Mount washer, screw on nut and tighten until the
boiler door gasket is tightly sealed.
18. Insert split pin.
19. Repeat steps 11 to 18 for the lower fitting.
Commissioning, inspection, maintenance
Type M148: Moving the hinge brackets to the… (cont.)
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20
140 0
-3
Fig. 10
140 0
-3
Fig. 11
20. Check that the boiler door is tightly sealed all the
way round and adjust if required.
All specified dimensions are test dimensions.
Danger
Leaks can result in poisoning through
escaping gas.
Check the gasket for correct seating and
realign if necessary.
Opening the boiler door(s)
A
B
Fig. 12
Undo screws A and open boiler door(s) B.
Note
There are versions of boiler door with hinges that open
to the right or left.
Replacing the boiler door hinges.
Commissioning, inspection, maintenance
Type M148: Moving the hinge brackets to the… (cont.)
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