Viessmann Vitomax LW Schulungshandbuch

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.

All manuals and user guides at all-guides.com

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

5673144

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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

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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

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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

5673144

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Symbol Meaning

Reference to other document containing

further information

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.

■Acoustic signal

■Fit new component.

■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

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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

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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

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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

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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

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