instructions rated output 8.0 to 20.0 mw viesmann type ... · preserve the boiler surfaces on the...

Operating and serviceinstructionsfor contractors

VIESMANN

Vitomax 200-LWType M64AOil/gas low pressure hot water boilersRated output 8.0 to 20.0 MW

VITOMAX 200-LW

5727 529 GB 5/2010 Please keep safe.

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Please follow these safety instructions closely to prevent accidents and mate-rial losses.

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Please noteThis symbol warns against therisk of material losses and envi-ronmental pollution.

NoteDetails identified by the word "Note" con-tain additional information.

Target group

These instructions are exclusivelydesigned for qualified contractors.■ Work on gas installations must only be

carried out by a registered gas fitter.■ Work on electrical equipment must

only be carried out by a qualified elec-trician.

■ The system must be commissioned byViessmann Industrieservice, the sys-tem installer or a qualified personauthorised by the installer.

Regulations

Observe the following when working onthis system ■ All legal instructions regarding the pre-

vention of accidents■ All legal instructions regarding envi-

ronmental protection■ Health and Safety at Work Act

(BetrSichV) [Germany]

■ The Code of Practice of relevant tradeassociations

■ Directive 97/23/EC, as well as the rel-evant safety regulations of the follow-ing countriesd DVGW, TRGI, TRF and VDE,

TRDa KG, ABV, LRG-K, LRV-K, DKBGc SEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS Directive1942: LPG, part 2

If you notice oil leaks and the smell ofgas

DangerEscaping fuel can lead to explo-sions which may result in veryserious injuries.■ Do not smoke. Prevent naked

flames and sparks. Do notpress any switches for lights orelectrical appliances.

■ Close the quick-acting fuelvalve and shut-off valve.

■ Open windows and doors.■ Remove all people from the

danger zone.■ Notify your gas or electricity

supply utility from outside thebuilding.

■ Shut off the electricity supply tothe building from a safe place(outside the building).

Safety instructions

Safety instructions

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If you smell flue gas

DangerFlue gas can lead to life-threat-ening poisoning.■ Shut down system.■ Ventilate boiler room.

Working on the system

■ Close the fuel shut-off valve andsecure against unintentional opening.

■ Isolate the system from the power sup-ply and check that it is no longer 'live',e.g. by removing the separate fuse orby means of a main isolator.

■ Safeguard the system against unau-thorised reconnection.

! Please noteElectronic assemblies can bedamaged by electrostatic dis-charges.Before beginning work, touchearthed objects, such as waterpipes, to discharge static loads.

DangerRisk of burning from hot surfacesso that■ steam line,■ hot water line,■ cleaning cover and closures/

plugs at the boiler system,■ boiler doors, as well as compo-

nents behind the doors,can all become very hot. Observesafety in the workplace!

Repair work

! Please noteRepairing components that fulfil asafety function can compromisethe safe operation of your sys-tem.Replace faulty components onlywith original Viessmann spareparts.

Auxiliary components, spare andwearing parts

! Please noteSpare and wearing parts thathave not been tested togetherwith the heating system can com-promise its function. Installingnon-authorised components andmaking non-approved modifica-tions or conversions can compro-mise safety and may invalidateour warranty.For replacements, use only orig-inal spare parts supplied orapproved by Viessmann.

Draining hot water

! Please noteThe blow-down and T.D.S. waterfrom boiler systems can reachtemperatures of up to and over100 °C.Set up the system in such a waythat this water is cooled to a tem-perature of < 35 °C before beingchannelled into the drainage sys-tem. If necessary, consult thelocal water board.

Safety instructions

Safety instructions (cont.)

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Draining condensate from the fluegas side

! Please noteWhen starting up the boiler sys-tem, or under certain operatingconditions, condensate may buildup in the flue passes, the flue gascollector and the downstreamflues, including the chimney.The system user must providesuitable installations to safelydrain such condensate.

Subject to the regulations in the countryconcerned, this condensate may need tobe neutralised. In such cases, consultthe local water board or the relevantauthorities in the country of installation.

Technical safety information

Any damage to the boiler that couldlead to risks requires an immediateboiler shutdown. If the boiler or any vessels suffer large-scale damage, notify the installation/service company immediately beforecarrying out any repairs. Observe all technical safety instruc-tions.In the case of damage, nothing shouldbe altered before an inspection takesplace unless it is to prevent further dam-age or to rescue somebody. The boiler house must only be enteredby authorised personnel. Always keepthe boiler house clean, well lit and freefrom all objects that do not belong thereand that might impair the operation. Theuse of any part of the system as a dryingarea is prohibited.

During operation, all required exits mustbe left unlocked and free from obstruc-tions. The operating personnel must logall events, such as faults, adjustments,consumption of spare parts and repairs.A log must be maintained of all regularreadings of the control instruments.Obvious signs at weld seams, leakingdamaged areas, severe corrosion,unusual characteristics of operatinginstruments and system components aswell as unusual noise inside the boilermust be notified immediately. Faults anddefects on the system that cannot beremedied by experts locally must be noti-fied to the manufacturer. Protect allboiler parts and control equipment fromrain, water leaks and expelled steam.Any damage or leaks that occur shouldbe repaired without delay.Apart from the relevant legal require-ments, all practical instructions issued byour technical personnel to the operatingpersonnel are applicable.

Safety instructions

Safety instructions (cont.)

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It is impossible to clarify and describe allpotential cases of indicators and possi-ble faults. After the system has beenoperated for a certain time, the regula-tions specified should therefore be sup-plemented in the light of experiencegained.

Safety instructions

Technical safety information (cont.)

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Operating instructionsOperating informationOperating tips....................................................................................................... 7Shutdown............................................................................................................. 7Maintenance information...................................................................................... 9

Service instructionsCommissioning, inspection, maintenanceSteps - commissioning, inspection and maintenance.......................................... 10Further details regarding the individual steps....................................................... 11

Water quality requirementsWater quality requirements.................................................................................. 22Using antifreeze in boilers.................................................................................... 24

Parts lists............................................................................................................ 26

Commissioning/service reports........................................................................ 28

Keyword index.................................................................................................... 29

Index

Index

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The boiler and heating systems mustonly be filled and operated with watercorresponding to the water qualityrequirements (see chapter “Water qual-ity requirements”). The system must becommissioned by the system installer ora qualified relevant expert authorised bythe installer.Record all actual values in a test report.These must be confirmed by the instal-ler, commissioning expert and the sys-tem user.Within 4 weeks of the combustion equip-ment being commissioned, the operatormust notify the local flue gas inspectoraccordingly [check local regulations].

We recommend operating the boiler con-stantly at a boiler water temperature of70 °C and at the required operating pres-sure. Even if no heat demand occurs fora longer period of time, it is still better tooperate the boiler continuously.In systems comprising several boilers, ofwhich one is constantly used as astandby boiler, only change the opera-tion over after longer intervals, e.g. dur-ing the annual inspection of the total sys-tem.

Operating instructions on pre-serving the water and hot gassides

Shutdown

To prevent corrosion setting in, during idle periods when the boiler is not pressurised,preserve the boiler surfaces on the flue gas and water sides, subject to the length ofthe period during which the boiler is taken out of use. There is a differentiationbetween wet preservation (during which exposure to oxygen is to be avoided) anddry preservation (during which moisture levels are to be minimised).

Brief operational interruption(1 to 2 days)

Water side

Recommendation: Maintain the boilerpressure and temperature. If this is notpossible and the boiler needs to be dep-ressurised for several days, we recom-mend the following:To prevent oxygen corrosion, approx.one hour before shutting the boiler down,add 2 to 3 times more oxygen binderthan usual to the feedwater until theboiler is shut down.

Flue gas side

Keep the heating surfaces dry. Removesevere contamination as it binds mois-ture.

Operating information

Operating tips57

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Longer interruptions of operation

Water side

Wet preservation if no risk of frost*1

exists

1. Fill the boiler up to the highest possi-ble level with treated feedwater. Toprevent oxygen corrosion, add anoxygen binder to the boiler water (e.g.sodium sulphite) in accordance withthe manufacturer's instructions. Testthe oxygen binder concentration atleast monthly and top up if required.For this, ensure a good admixing withthe boiler water (thermal or mechani-cal agitation).

2. In multi boiler systems if only someboilers must be preserved, these canbe filled with desalinated boiler waterfrom the boilers that remain in use.This will also maintain the tempera-ture.

3. Maintaining pressure in a fully filledboiler using nitrogen (preferably nitro-gen 5.0) of 0.1 to 0.2 bar can preventcorrosion.

Dry preservation if there is a risk offrost*1 or prolonged idle period

Drain the boiler at 90 °C and then openthe water connections.

Dry the boiler thoroughly and fill withdessicant (e.g. silica gel) in accordancewith the manufacturer's details. Ensure that the dessicant does not comeinto contact with the boiler material. Thenclose the boiler again. Check in regularintervals whether the dessicant is stillable to absorb moisture.

Flue gas side

Thoroughly clean and dry the surfaceson the flue gas side. Maintain the alkaline balance of thewash water (pH 8-9, in the case ofammonia pH 10). After thoroughly drying the surfaces, pre-serve them with a thin film of graphite orvarnish. Keep the surfaces dry during the idleperiods (by adding a dessicant such assilica gel or by air circulation via a con-nected dryer).

Further details

For further details, see the operatinginstructions for preservation on the waterand hot gas side or the VdTÜV data-sheets (no. 1465, Oct. 1978) and theVGB (no. R116H, 1981) [or local regula-tions].

*1 See chapter "Using antifreeze in boilers"


Shutdown (cont.)

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We recommend having the boiler systemserviced regularly to ensure fault-free,efficient and environmentally responsi-ble operation.The boiler should be cleaned regularly toprevent the flue gas temperature risingwith increasing contamination, whichleads to higher energy consumption.We recommend the installation of a fluegas thermometer. Monitoring the fluegas temperature highlights incorrectburner adjustment and the level of boilercontamination.Excessive flue gas temperaturesthrough contamination or altered burneradjustment reduce efficiency. Wherenecessary, clean the boiler or adjust theburner settings.


Maintenance information57

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For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

• • • 1. Commissioning the system........................................... 11

• • 2. Shutting down the system............................................. 12

• 3. Removing the burner (if required)................................. 13

• • 4. Opening the boiler doors............................................... 13

• • 5. Opening the cleaning door and cleaning cover........... 14

• 6. Cleaning the heating surfaces and flue gas collector. 14

• • • 7. Checking all seals/gaskets and packing cords on theflue gas side

• • 8. Cleaning the sight glass................................................ 14

• • • 9. Checking thermal insulation parts and gaskets.......... 15

• • • 10. Closing boiler doors....................................................... 16

• • • 11. Fitting the cleaning door and cleaning cover.............. 16

• • 12. Installing the burner....................................................... 17

• • 13. Checking all water connections for leaks

• • 14. Checking the inspection ports for leaks...................... 17

• 15. Checking the water chamber for deposits................... 19

• • • 16. Checking the water level and system pressure

• • • 17. Checking the safety and control equipment

• • • 18. Checking the safety valve.............................................. 19

• • 19. Checking all water connections for leaks after theboiler has been filled...................................................... 19

• • 20. Checking the water quality............................................ 20

• • 21. Checking the thermal insulation

• • • 22. Checking the installation room ventilation

• • • 23. Checking the flue pipe for tightness

• • 24. Adjusting the burner...................................................... 21

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

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Commissioning the system

Details provided by the burnermanufacturer and regardingaccessories

01. Open the boiler doors and checkthat the turbulators (if fitted) are fullypushed into the hot gas flues.

02. Check that the installation roomventilation is unobstructed.

03. Filling the heating system with waterand venting it.

! Please noteUnsuitable water quality candamage the boiler body.Fill and operate the heatingsystem with water that com-plies with the "Water qualityguidelines" from page 22onwards.

NoteRecord the fill volume and totalhardness on page 20.

04. Check the system pressure.

05. Check all fitted components, suchas pipework, valves, controllers,pumps etc. for function and leaks.

06. Check the fuel supply for leaks andpressure.

07. Open the flue gas damper (if instal-led).

08. Check that the cleaning aperture onthe flue outlet is closed.

09. Check that the dewatering line (ifinstalled) is correctly connected tothe condensate connection.The condensate connection mustbe sealed when not in use.

10. Open the shut-off valves in the oillines (at the oil tank and filter) oropen the gas shut-off valve.

11. Switch ON the main isolator, theON/OFF switch for the boiler drivesand burner in this order.

Burner manufacturer's oper-ating instructions

12. Start the boiler at a low output (max.30 %) and heat up to a temperatureof approx. 30 K below the operatingtemperature.The condensate drains must beopen and any condensate must becorrectly collected or drained.

13. After the required flow temperaturehas been achieved, open the boilerreturn valve, the feedwater valve ifrequired and then, very slowly, theboiler flow valve.

14. Only then, enable the full burnerload.

15. While the system heats up, checkthe correct function of all control andsafety equipment.

16. Observe the pressure and temper-ature test equipment.


Further details regarding the individual steps57

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17. Check the fittings for leaks andtighten if required.

Closure Dimen-sions

Torque

Hand-hole

100 mmx150 mm,M16

100 Nm

18. After approx. 50 hours, check theboiler doors and cleaning cover forleaks and retighten all screws (tor-que approx. 20 Nm).

Shutting down the system

DangerHeating water escaping underpressure will injure bystanders.Only open connections andinspection ports on the heatingwater and flue gas side if theboiler has been depressurisedand cooled.

! Please noteDraining the boiler with a suctionpump will create negative pres-sure inside the boiler.Only drain the boiler with a suc-tion pump if the air vent valve isopen.

! Please noteHot water can cause damage.Never drain hot water into thedrainage system.Ensure adequate cooling.

1. Shut down the burner.

2. Close the shut-off valves in the oillines (at the oil tank and filter) or thegas shut-off valve.

3. Isolate the system from the powersupply.

4. Close all valves.


Further details regarding the individual steps (cont.)

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Removing the burner (if required)

A

B

1. Remove the fuel supply line.For pressure-jet gas burner:Remove the gas supply pipe.

DangerEscaping gas leads to a risk ofexplosion.Test the tightness of all gasconnections.

2. Undo screws A and remove burnerwith burner plate B.

Opening the boiler doors

AB Undo screws A on boiler doors B andswing the doors open.



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Opening the cleaning door and cleaning cover

B

A

Undo nuts and remove cleaning coverB. Open the cleaning door A.

Cleaning the heating surfaces and flue gas collector

A

B

1. Clean flues A, combustion chamberB and reversing chamber with suit-able cleaning equipment and removecombustion residues.

2. Remove combustion residues fromthe flue gas collector (back).

Cleaning the sight glass

Check the sight glass with gaskets A forleaks and clean.



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Checking thermal insulation parts and gaskets

A

Check thermal insulation parts A andgaskets B.Replace faulty parts.



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Closing boiler doors

1. Close boiler doors A.

2. Tighten boiler door screws evenly(torque approx. 20 Nm).

Fitting the cleaning door and cleaning cover

B

A

1. Secure both cleaning covers B sothey seal.

2. Close cleaning door A and secure itso it seals.



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Installing the burner

A B C

1. Fit burner plate B with screws A toburner flange C.

2. Seal annular gap (if present) betweenburner head and insulation rings withheat-resistant insulation material(see parts list).

3. For pressure-jet gas burner:Fit the gas supply pipe.

DangerEscaping gas leads to a risk ofexplosion.Test the tightness of all gasconnections.

Checking the inspection ports for leaks

DangerBoiler components that are notthermally insulated can be sub-ject to high temperatures that cancause burns.Take care with hot surfaces.

NoteReplace the gaskets every time the con-nections and inspection ports areopened.Only use gaskets approved in accord-ance with TRD 401, appendix 1, VdTÜV[or local regulations].

Installation instructions of thegasket manufacturer.



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Caution - hot surface

A Cleaning aperturesB Inspection port

C Handhole



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Checking the water chamber for deposits

1. Fully drain the boiler.

DangerHeating water escaping underpressure will injure bystand-ers.Only open connections andinspection ports on the heat-ing water and flue gas side ifthe boiler has been depres-surised and cooled.

! Please noteDraining the boiler with a suc-tion pump will create negativepressure inside the boiler.Only drain the boiler with asuction pump if the air ventvalve is open.

! Please noteHot water can cause dam-age.Never drain hot water into thedrainage system.Ensure adequate cooling.

2. Clean the water chamber (hose it out)and remove deposits via the drain. Incase of harder deposits that cannotbe removed by hosing down, carryout chemical cleaning using anapproved descaling agent.

3. Clean sealing surfaces of the hand-hole cover and thread of the inspec-tion port and replace the gaskets.Seal the thread using hemp.Retighten new gaskets after commis-sioning and check again after 24hours run.

Checking the safety valve

Manufacturer's details

Checking all water connections for leaks after the boiler hasbeen filled

Replace the gaskets every time a con-nection has been opened.

1. Clean the sealing face.

2. Replace the gasket.

3. Retighten all closures after commis-sioning.



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Checking the water quality

Enter the amount of top-up water and the total hardness of the boiler water into thetable.For water quality requirements, see page 22.

Fillwa-ter

Top-upwater

Meterread-ing

Totalwatervolume

Total hard-ness

pHval-ue

Water treat-ment

Date

m3 m3 m3 m3 Feed-

waterBoil-erwa-ter

Boil-erwa-ter

Medi-um

Meter-ing vol-ume

— — — — — — — — — — — — — — — — — —

The total hardness must not exceed 0.02 mol/m3 (0.11 °dH).The pH value should be between 9.0 and 10.5.



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Adjusting the burner

Burner manufacturer’s details

Adjust the maximum fuel oil or gasthroughput of the burner to the ratedboiler output.

Permissible flow temperature 110 °CBoilersize*2

Rated output Resistance on flue gas sideHEL Gas HEL*3 GasMW MW Pa mbar Pa mbar

1 7.75 8.00 1020 10.2 1130 11.32 8.55 10.00 900 9.0 1180 11.83 10.12 12.00 990 9.9 1570 15.74 11.78 14.20 850 8.5 1420 14.25 13.43 16.50 880 8.8 1540 15.46 15.09 20.00 920 9.2 1880 18.8

Permissible flow temperature 120 °CBoilersize*2

Rated output Resistance on flue gas sideHEL Gas HEL*3 GasMW MW Pa mbar Pa mbar

1 7.75 8.00 1020 10.2 1130 11.32 8.55 10.00 900 9.0 1180 11.83 10.12 12.00 990 9.9 1570 15.74 11.78 14.20 850 8.5 1420 14.25 12.88 16.50 800 8.0 1540 15.46 12.88 16.74 650 6.5 1300 13.0

To protect the system against dew pointcorrosion, the full load must be set to therated boiler output and must not beswitched off during the summer months(full load at constant standby).

The minimum boiler water temperatureis 70 ºC. Adjust the return temperatureraising facility to a minimum temperatureof 50 ºC (operation with oil) or to 55 ºC(operation with gas).

*2 The last digit of the part number indicates the boiler size.*3 With a maximum permissible combustion output



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Heating systems with rated operating temperatures up to 100 ºC(VDI 2035)

Water used in heating systems mustmeet the chemical values in the DrinkingWater Ordinance [Germany]. If wellwater or similar is used, check its suita-bility before filling the system.Prevent excessive scale build-up (cal-cium carbonate) on the heating surfaces.For heating systems with operating tem-peratures up to 100 °C, VDI Directive2035 sheet 1 "Prevention of damage inhot water heating systems - scaling inDHW and hot water heating systems"applies [in Germany] with the followingstandard values. Please see the explan-ations in VDI Directive 2035 for furtherinformation.

Total output in kW > 600Total of alkaline earths mol/m3 < 0.02Total hardness in °dH < 0.11

The standard values assume the follow-ing:■ The volume of fill and top-up water of

the heating system during its servicelife will not exceed three times thewater content of the heating system.

■ The specific system volume is lessthan 20 l/kW output. In multi boiler sys-tems, apply the output of the smallestboiler.

■ All measures to prevent corrosion onthe water side in accordance with VDI2035 Sheet 2 have been implemented.

Soften the fill & top-up water in heatingsystems operating under the followingconditions:■ The total of alkaline earths in the fill &

top-up water exceeds the standardvalue.

■ Higher fill & top-up water volumes areexpected.

Observe the following during planning:■ Install shut-off valves in different sec-

tions. This prevents the need for drain-ing the entire heating water in case ofrepairs or system expansion.

■ Install a water meter to record theamount of the fill & top-up water. Enterthe volume of water and the waterhardness into the boiler serviceinstructions.

Operating information:■ Commission the system step by step,

starting with the lowest boiler outputand at a high heating water flow rate.This prevents a localised concentra-tion of limescale deposits on the boilerheating surfaces.

■ During expansion or repair work, onlydrain the necessary sections.

Water quality requirements


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■ Where water treatment is required,treat even the first fill of the heatingsystems prior to commissioning. Thisalso applies to any subsequent filling,e.g. when adding top-up water, after arepair or after system expansion.

■ Filters, dirt traps and other blow-downor separating facilities in the heatingwater circuit must be checked,cleaned and activated more frequentlyafter commissioning or recommission-ing, and later on as required, subjectto the water treatment applied (e.g.water softening).

The build-up of limescale deposits on theheating surfaces will be minimised ifthese instructions are observed.

Any limescale deposits that have formedbecause the requirements to VDI Direc-tive 2035 have not been observed will inmost cases already have caused areduction in the service life of the instal-led heating equipment. Removing thelimescale deposits is one option forrestoring operational viability. Thismeasure must be carried out by theViessmann Industrieservice or a special-ist company. Inspect the heating systemfor possible damage prior to returning itinto use. It is essential that the faultyoperating parameters are corrected toprevent renewed formation of excessivescale deposits.

Prevention of damage through corrosion on the water side

The corrosion resistance of ferrousmaterials on the heating water side ofheating systems and boilers depends onthe absence of oxygen in the heatingwater.The oxygen introduced into the heatingsystem with the first fill and the top-upwater reacts with the system materialswithout causing damage.The characteristic blackening of thewater after some time in use indicatesthat free oxygen is no longer present.The technical rules and in particular VDIDirective 2035-2 therefore recommendthat heating systems are designed andoperated so that a constant ingress ofoxygen into the heating water is preven-ted.

Opportunities for oxygen ingress duringoperation:■ Through open expansion vessels

overflowing■ Through negative pressure in the sys-

tem■ Through gas-permeable components

Sealed systems – e.g. systems with adiaphragm expansion vessel – offergood protection against the ingress ofairborne oxygen into the system if theyare correctly sized and operate at thecorrect pressure.At every part of the heating system, evenat the suction side of the pump and underall operating conditions, the systempressure should be above ambientatmospheric pressure.


Water quality requirements (cont.)

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The pre-charge pressure of the dia-phragm expansion vessel should bechecked at least during the annual serv-ice.The use of permeable components, e.g.plastic pipes that are permeable to gasin underfloor heating systems, should beavoided. Provide system separation ifsuch components are neverthelessused. This must separate the water flow-ing through the plastic pipes from otherheating circuits, e.g. from the boiler, bythe provision of a corrosion resistantheat exchanger.No further anti-corrosion measures arerequired for sealed hot water heatingsystems subject to the above pointsbeing observed.However, take additional precautionswhere there is a risk of oxygen ingress,for example by adding oxygen bindersodium sulphite (5 - 10 mg/litre into theexcess). The heating water should havea pH value between 9.0 and 10.5.

Different conditions apply to systemsthat contain aluminium components.Where chemicals are used as part of thecorrosion protection, we recommendthat the manufacturer of the chemicalsissues a certificate of suitability of theadditives with regard to the boiler mate-rials and the materials of the other heat-ing system components.We recommend you refer questions ofwater treatment to Viessmann industrialservices or an appropriate specialist.Further details can be found in VDIDirective 2035-2 and EN 14868.

Using antifreeze in boilers

Viessmann boilers are designed andbuilt for water as a heat transfer medium.To protect boiler systems from frost, itmay be necessary to treat the boiler orcircuit water with antifreeze.

When doing so, observe the following:■ As a general principle, follow the spec-

ifications given by the antifreeze man-ufacturer.

■ The properties of antifreeze and waterare very different.

■ The temperature stability of the anti-freeze must be sufficient for the par-ticular application.

■ Check the compatibility with sealingmaterials. If other sealing materialsare used, take this into account whendesigning the system.


Water quality requirements (cont.)

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■ Antifreeze developed especially forheating systems contains inhibitorsand buffer substances for corrosionprotection as well as glycol. Whenusing antifreeze, always observe themanufacturer's instructions regardingminimum and maximum concentra-tions.

■ The concentration must never fallbelow the prescribed minimum level,subject to the required frost protectiontemperature. Check and adjust the pHvalue and frost protection (measurethe density) regularly, at least once ayear, according to the manufacturer'sinstructions.

■ Check with the relevant supplierwhether antifreeze may affect systemcomponents that are not part of theboiler, such as pumps, electrically andpneumatically driven valves, othertypes of valves, gaskets, etc.

■ If the system is filled with antifreeze, itmust be marked accordingly.

■ If a boiler system is changed to oper-ate without antifreeze, flush the sys-tem in order to remove all traces of theantifreeze.

■ The quality of the boiler and feedwatermust meet the requirements of VDIDirective 2035.

■ The systems must be designed assealed unvented systems, as the anti-freeze inhibitors decrease rapidly if air-borne oxygen is allowed to enter.

■ Diaphragm pressure compensationvessels must comply with DIN 4807.

■ Solder connections should preferablybe made with Ag or Cu hard solder. Ifliquids containing chlorides are usedfor soft soldering, any deposits mustbe removed from the circuit afterwardsthrough thorough flushing. A higherchloride content in the heat transfermedium can cause corrosion damage.

■ Only use oxygen diffusion-resistanthoses or metal hoses for flexible con-nections.

■ Never equip the system on the primaryside with zinc-plated heat exchangers,cylinders or pipes as zinc can be cor-roded by glycol/water mixtures.

■ To avoid the risk of corrosion, ensurethat there is no difference in electricalpotential between system compo-nents that are in contact with anti-freeze.

■ Route all pipes in such a way that cir-culation cannot be interrupted by gascushions or deposits.

■ The water circuit must always be filledup to the highest point with the heattransfer medium.

■ After filling, ensure there are no moreair cushions in the system. When thetemperature falls, gas cushions formnegative pressure and this can drawair into the system.

■ After initial filling and commissioning,but after 14 days at the latest, cleanthe integral dirt trap so the heat trans-fer medium can flow freely.

■ Following any losses through leaks ordrawing off, top up the antifreeze sol-ution according to the concentrationalready in place. Establish the volumeof antifreeze as a check.


Using antifreeze in boilers (cont.)

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When ordering spare parts:Please enter the serial number and type,as well as the number of articlesrequired.

Obtain standard parts from your localsupplier. A corresponding amount ofinstallation adhesive is provided.

Parts lists

Parts lists

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Boiler size*2

1 2 3 4 5 6Pos. Component Quan-

tityQuan-

tityQuan-

tityQuan-

tityQuan-

tityQuan-

tity1 Packing per boiler

door

2 Packing per boilerdoor

3 Insulation ring 4 Burner connection

packing

5 Cleaning coverpacking

6 Rear boiler floorpacking

7 Packing per clean-ing aperture

8 Handhole gasket100 x 150 mm

9 Seal ring set

Please order individual parts from:Viessmann IndustrieserviceTel.: 0049-30/6602 389Fax.: 0049-30/6602 136Email: [email protected]: www.viessmann-industriekessel.de

*2 The last digit of the part number indicates the boiler size.

Parts lists

Parts lists (cont.)

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Commissioning Service Service date: by:

Service Service Service date: by:




Commissioning/service reports

Commissioning/service reports

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AAdjusting the burner...........................21Anti-corrosion measures....................24

BBurner, removal.................................13

CChecking gaskets...............................15Checking the inspection ports............17Checking thermal insulation parts......15Checking the safety valve..................19Checking the water chamber.............19Checking water connections..............19Chemicals for corrosion protection....24Cleaning the flue gas collector...........14Cleaning the heating surfaces...........14Cleaning the sight glass.....................14Commissioning....................................7Commissioning the system................11Corrosion on the water side (preven-tion)....................................................23

DDiaphragm expansion vessel.............23

EExpansion vessel...............................23

FFill and top-up water..........................20Filling the heating system with water. 11Fitting the cleaning door.....................16

IInstalling the burner...........................17

MMaintenance information......................9

OOpening the boiler doors....................13Opening the cleaning door.................14

SShutdown.............................................7Shutting down the system..................12

TTotal alkaline earths...........................11Total boiler water hardness................11Total hardness of the boiler water......20

VVenting the heating system................11

WWater quality................................20, 22Water side corrosion (prevention)......23Water treatment.................................24

Keyword index

Keyword index57

27 5

29 G

B

30

5727

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31

5727

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32

Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: [email protected]

Viessmann Werke GmbH&Co KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com

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instructions rated output 8.0 to 20.0 mw viesmann type ... · preserve the boiler surfaces on the...

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