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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3
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.)
6152553

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.)
6152553

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.)
6152553

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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7
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
6152553
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.)
6152553
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
6152553
Service

10
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.)
6152553
Service