Viessmann Vitomax LW Training manual

Operating and service instructions
for contractors
Viesmann
Vitomax LW
Type M22
Type M62
Type M82
Low pressure hot water boiler
VITOMAX LW
6152553 GB 4/2020 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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
■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
commissioning. Ensure the installation
room is well ventilated.
Before working on the system
■Close the fuel shut-off valve and
secure against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, 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 recon-
nection.
Safety instructions
Safety instructions
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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 and the components
behind them
Observe occupational safety. Wear
protective clothing where neces-
sary.
Electrostatic discharge
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Before beginning work, touch
earthed objects, such as heating or
water pipes, to discharge any static.
Repair work
!Please note
Repairing components that fulfil a
safety function 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 tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Dismantling and disposal
When dismantling and disposing of ther-
mal insulation materials and gaskets/
seals on the gas side, observe the appli-
cable safety regulations.
The product and its components must
be disposed of according to local envi-
ronmental regulations.
This applies in particular to the disposal
of thermal insulation materials and gas-
kets/seals on the gas side.
Safety instructions for operating the system
General
The materials included in the product
pose no threat to health during opera-
tion.
Safety instructions
Safety instructions (cont.)
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4
If you notice oil leaks or smell gas
Danger
Escaping fuel can lead to explo-
sions which may result in very seri-
ous injuries.
■No smoking! Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Close the quick-action fuel valve
and shut-off valve.
■Ventilate the boiler house.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply 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 systems can reach tem-
peratures of over 100 °C.
Before draining water into the sew-
age system, allow it to cool to a
temperature of < 35 °C. If neces-
sary, consult the local water board.
Draining condensate from the flue
gas side
!Please note
When starting up the boiler system,
or under certain operating condi-
tions, condensate may form in the
flue passes, the flue gas collector
and the downstream flues, including
the chimney.
This 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 neces-
sary in order to rescue people or prevent
further damage.
Safety instructions
Safety instructions (cont.)
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5
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 immedi-
ately 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 rem-
edied 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.)
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6
1. Information Symbols ................................................................................................. 7
Note ....................................................................................................... 7
Intended use .......................................................................................... 7
2. Water quality Standard values for water quality .......................................................... 9
■Flow temperatures ≤ 100 °C (VDI 2035 Part 1-2) ............................... 9
■Flow temperatures > 100 °C (VdTÜV MB 1466) ................................ 10
■Preventing water side corrosion ......................................................... 10
3. Commissioning Commissioning ...................................................................................... 12
Commissioning after boiler idle periods, cold starts .............................. 12
4. Normal operation Operating conditions .............................................................................. 13
Protecting the boiler from dew point corrosion ...................................... 13
Notes on condensate drainage .............................................................. 14
5. Notes on decommission-
ing and preservation
Decommissioning .................................................................................. 15
What preservation is for ......................................................................... 15
Brief interruption in operation ≤ 3 days .................................................. 15
■Treatment on the water side ............................................................... 15
■Treatment on the flue gas side ........................................................... 15
Interruption in operation > 3 days .......................................................... 15
■Treatment on the water side ............................................................... 15
■Applicable regulations ........................................................................ 16
Treatment on the flue gas side .............................................................. 16
6. Maintenance Information on maintenance .................................................................. 18
■Preventing excessive flue gas temperatures ...................................... 18
7. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 19
8. Troubleshooting Diagnosis ............................................................................................... 31
9. Wearing parts Wearing parts and gaskets .................................................................... 32
■Viessmann Industrial Service contact details ..................................... 33
10. Commissioning/service
reports
Reports for commissioning, inspection and maintenance ..................... 34
Start-up report ........................................................................................ 34
11. Keyword index ................................................................................................................ 38
Index
Index
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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.
Intended use
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
Symbols
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Information

8
Intended use also includes:
■Use the specified equipment and auxiliary materials
(lubricants, spare and wearing parts, etc.).
■Equip for operation according to the country-specific
and site-specific regulations.
■Indoor installation in a building or container.
■Use only approved components.
Other limit parameters to observe
Boiler with condensing ECO
■Fuel: Natural gas and EL fuel oil (only for emergency
operation)
■Minimum water inlet temperature: 10 °C
■Maximum permissible temperature (water side): 110
°C
■Maximum permissible operating pressure: 6 bar
■Boiler flow/return temperature: Maximum spread
50 K
■Maximum flue gas temperature: 300 °C
Boiler with non-condensing ECO
■Fuel: Natural gas and EL fuel oil (only for emergency
operation)
■Minimum water inlet temperature: 65 °C
■Maximum permissible temperature (water side):
150 °C
■Maximum permissible operating pressure: 16 bar
■Boiler flow/return temperature: Maximum spread
40 K
■Maximum flue gas temperature: 300 °C
Note
Higher temperatures on request
Note
Start-up reports must be filled in after commissioning.
For start-up reports, see page 34.
Information
Intended use (cont.)
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Information

9
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 chapter "Stand-
ard values for water quality" are complied with
Recommendation
Use a chemical water treatment system in the boiler
system.
Request a quotation from Viessmann (for contact
details, see page 33).
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. In
the case of multi boiler systems: The output of the
smallest steam boiler or hot water boiler applies here
■All measures to prevent corrosion on the water side
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. 1
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 in the boiler 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
■Only fill the heating system with treated water:
Occasions when this will be necessary:
–Commissioning
–Recommissioning
–After repairs or system expansion
–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 them and check they are working correctly:
How often:
–After commissioning and reinstallation: At shorter
intervals
–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
Remedies:
■Remove deposits immediately
■Restore operational viability of the boiler system
■Check the boiler system for damage before recom-
missioning
■Ensure that excessive limescale deposits (scaling)
cannot recur
■Rectify incorrect operating parameters
Water quality
Standard values for water quality
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Recommendation
Commission Viessmann Industrial Service (for contact
details, see page 33) or another contractor to carry
out the relevant measures.
Flow temperatures > 100 °C (VdTÜV MB 1466)
Operating with circulating water with low salt con-
tent
Note
Only use fill and top-up water with low salt con-
tent, e.g. desalinated water, permeate or condensate.
Systems using mixed condensation:
These systems generally 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. 2
Preventing water side corrosion
General
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.
*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.
Water quality
Standard values for water quality (cont.)
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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, for example.
Recommendation for diaphragm expansion vessel
Check the pre-charge pressure during the annual serv-
ice at the latest.
Pressure maintaining systems and corrosion
"General engineering information" chapter 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
Additional protection against oxygen ingress
■Add an oxygen binder (excess of 5 - 10 mg
Na2SO3/l).
■Adjust the pH value of the heating water to 8.2 - 9.5.
Use of aluminium components
Bear in mind 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
Water quality
Standard values for water quality (cont.)
6152553
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Note
When commissioning, ensure that the installation room
is well ventilated, as unpleasant odours may occur.
Authorised to commission the boiler:
■Viessmann Industrial Service (for contact details, see
page 33) or
■The system installer or
■An approved contractor or institution nominated by
the system installer
During commissioning, country-specific require-
ments must be observed, e.g.:
■Presence of a competent expert authority
■Preparation of all necessary test reports; see 34
■Required signatories:
–System installer
–Official expert authority
–System user
■The flue gas inspector (where applicable) should be
notified of commissioning within 4 weeks
Commissioning after boiler idle periods, cold starts
Cold start to EN 12953-3
Boiler start-up from ambient pressure at room temper-
ature to normal operation (full pressure cycle)
See engineering information for boiler cold/warm
start
!Please note
A start-up report must be filled in for each cold
start. For start-up reports, see page 34.
Start-up reports are a prerequisite for verifying
the warranty.
!Please note
Prevent unnecessarily high mechanical stress
and condensate formation in the flue gas during
a cold start. Wait until the boiler has reached
normal operating conditions before slowly heat-
ing up the consumer network.
Commissioning
Commissioning
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Operating conditions Requirements/notes
M22 M62/M82 with-
out econo-
miser
M62/M82 with
condensing
ECO
M62/M82 with
non-condens-
ing ECO
1. Heating water flow rate No minimum heating water flow rate required
2. Boiler return temperature (minimum
value)
■Gas operation: 55 °C 55 °C 55 °C 65 °C
■Oil operation: 50 °C 50 °C 50 °C 65 °C
3. Minimum flow temperature 70 °C
4. Minimum water inlet temperature See boiler re-
turn tempera-
ture
Recommenda-
tion for con-
densing ECO:
30 °C for high
condensation
rate
See boiler re-
turn tempera-
ture
5. Max. temperature spread
For gas and oil operation 50 K 50 K 50 K 40 K
6. Multi stage burner operation None
7. Modulating burner operation None
8. Setback mode
Single boiler system Operation with minimum flow temperature
Multi boiler system
■Lead boiler Operation with minimum flow temperature
■Lag boiler Lag boilers can be shut down
Weekend setback See setback mode
Tab. 3
Note
Boiler types M62 and M82: Condensing and non-
condensing ECOs
Use EL fuel oil only as a substitute fuel for condensing
and non-condensing ECOs.
If using S fuel oil, only use on-site economisers that
are suitable for this purpose.
Note
For boiler types M62 and M82 without economiser: If
burning S fuel oil, the average boiler water tempera-
ture must be at least 90 °C according to DIN 51603-5.
Boiler datasheet
See chapter "Standard values for water quality"
on page 9
Recommendation
Do not interrupt boiler operation, even if heat is tempo-
rarily not being drawn off.
Maintain the following at all times
■Minimum flow temperature
■Specified operating pressure
Multi boiler systems with a boiler on permanent
standby:
Operational changeovers should be infrequent,
for example during the annual inspection of the overall
system.
Protecting the boiler from dew point corrosion
■Adjust the full burner load to the rated boiler heating
output.
■Leave the boiler switched on even during the sum-
mer months (full load on constant standby).
■The minimum flow temperature of 70 °C is not under-
shot.
■In multi boiler systems, boilers can be shut down by
having boiler water from the rest of the boiler system
flow through them.
Normal operation
Operating conditions
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During operation, acidic condensate forms in the boiler
and flue pipe. With gas combustion, the pH values are
between 3 and 4. Drain off condensate in accordance
with regulations.
Condensate from systems > 200 kW must be neutral-
ised. Condensate is treated by a neutralising agent in
the neutralising system once it is discharged from the
system.
The neutralising agent raises the pH value to between
6.5 and approx. 9.
Code of Practice DWA-A 251 "Condensate from
condensing boilers"
Normal operation
Notes on condensate drainage
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Decommissioning means shutting down the system via
the circuit 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, e.g. over a
weekend, the boiler should be left to continue operat-
ing.
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 in areas on the
flue gas side and on the water side 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. 4
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. 5
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 chem-
ical manufacturers.
Brief interruption in operation ≤ 3 days
Treatment on 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. 6
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.
Treatment on the flue gas side
■Keep heating surfaces dry.
■Remove severe contamination as it binds moisture.
Interruption in operation > 3 days
Treatment on the water side
Dry preservation
Note
Restarting the system quickly is not possible.
Applications:
■Prolonged boiler idle periods
■Risk of frost
See chapter "Using antifreeze in boiler systems"
in the technical guide
Notes on decommissioning and preservation
Decommissioning
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Application:
1. Drain the hot water boiler (boiler including econo-
miser) at < 90 °C.
!Please note
Draining hot water into the sewage system
causes environmental damage.
Therefore cool the water to < 35 °C before-
hand. If necessary, collect it in containers. If
necessary, consult the local environment
authority.
2. Open the closures on the water side.
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.
3. Check the concentration of the oxygen binder reg-
ularly and at least once a month; if necessary, add
more oxygen binder.
Preserving single boilers in a multi boiler system
The relevant boilers are kept at temperature by having
water from the rest of the boiler system flow through
them.
Corrosion protection of a full 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
Treatment on 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.
Notes on decommissioning and preservation
Interruption in operation > 3 days (cont.)
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Recommendation for areas with high relative
humidity
Do not use dry preservation in areas with high relative
humidity due to the special 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
Notes on decommissioning and preservation
Treatment on the flue gas side (cont.)
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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 33)
–Other authorised contractors
Preventing excessive flue gas temperatures
Excessively high flue gas temperatures make the system less efficient
Cause of fault Remedy
Altered burner adjustment Adjust the burner correctly
Contaminated boiler system Clean the boiler system
Tab. 7
Recommendation
Constant monitoring of the flue gas temperature
Maintenance
Information on maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 20
• • 2. Shutting down the system................................................................................................. 21
•3. Removing the burner (if required).................................................................................... 21
• • 4. Opening the boiler door(s)................................................................................................ 22
• • 5. Removing the inspection port closures........................................................................... 22
•6. Removing and cleaning the turbulators (if installed)..................................................... 23
•7. Cleaning the heating surfaces and flue gas collector.................................................... 23
••• 8. Checking the gaskets and packing cords on the flue gas side
• • 9. Cleaning the sight glass.................................................................................................... 23
••• 10. Checking the thermal insulation components and gaskets........................................... 24
••• 11. Inserting turbulators (if installed) and closing boiler door(s)........................................ 25
••• 12. Closing and securing the inspection ports..................................................................... 25
• • 13. Mounting the burner (if required)..................................................................................... 26
•14. Checking the water chamber for deposits (M62, M82)................................................... 27
• • 15. Checking the connections and inspection ports on the water side for leaks.............. 27
••• 16. Checking the water level and system pressure
••• 17. Checking the safety and control equipment.................................................................... 28
••• 18. Checking the safety valve................................................................................................. 28
• • 19. Checking the water quality................................................................................................ 28
• • 20. Checking the thermal insulation
••• 21. Checking the installation room ventilation
••• 22. Checking the flue pipe for leaks
• • 23. Adjusting the burner.......................................................................................................... 29
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
6152553

20
Note
Take notes for the reports during the process. Fill in
the start-up reports.
For start-up reports, see page 34
Information on burners and accessories
01. Check that the fuel being used is permissible for
the current system configuration.
02. Open the boiler door(s).
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 fill volume and overall water hard-
ness.
07. Check the system pressure.
08. Check all fitted components for function and leaks.
09. Check the fuel supply pressure and ensure there
are no leaks.
10. Open the flue gas gate valve and 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
Burner operating and service instructions
!Please note
Only adjust the burner at the end of these
instructions.
15. Start the system at a low heating output (max. 30
%).
16. Open the condensate drain on the boiler.
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 on the boiler.
21. Enable full burner load.
22. During heat-up:
■Monitor the function of the control and safety
equipment.
■Monitor the pressure and temperature.
■Fill in the start-up report.
23. Check the closures for leaks and tighten if neces-
sary (see table on page 21).
24. After approx. 50 hours run, check the following
assemblies for leaks:
■Boiler door(s)
■Closures for the inspection port (tighten screws
if necessary)
Commissioning, inspection, maintenance
Commissioning the system
6152553