User Manual - Vitomax 200
Contents
1. 13 Anti corrosion measures 27 B Boiler door M ODOMING iirinn eii 15 Boiler doors Meca E 18 Burner M AJUSUN Garida caine 23 ianao eE A E AT 19 REMOVA kreiseri reinii 15 c Checking gasketS 17 Checking the inspection port for tight MESS a R RRO 19 Checking thermal insulation compo NEMIS re EE gin 17 Checking the safety valve 21 Checking the water chamber for depos liscia lati 21 Checking the water quality 22 24 Checking water connections 21 Chemicals for corrosion protection 28 Cleaning cover m Opening ori 16 Mm SECUTNG iaia 18 Cleaning door m Opening 16 MI SECUNQ ici 18 Cleaning flue gas collector 16 Cleaning heating surfaces 16 Cleaning the sight glass 16 Keyword index COMMISSIONINQ ii 7 Corrosion on the water side preven MOM riot 27 D Diaphragm expansion vessel 27 E Expansion vessel 27 F Fill and top up water 22 25 M Maintenance instructions 10 O Operating ChECKS 8 S Safety valve checking 8 Saline waten i aonr ai 25 MUTA OWN scie 8 System m COMMISSIONING 13 m Shutting dOWN eeeeeeeeeeeeees 14 T Total hardness of the boiler water 22 Ww Water side corrosion2. heating systems subject to the above points being observed However take additional precautions where there is a risk of oxygen ingress for example by adding oxygen binder sodium sulphite 5 10 mg litre into the excess The pH value of the heating water should be between 9 0 10 5 Different conditions apply to systems that contain aluminium components 27 Water quality requirements Water quality requirements cont Where chemicals are used as part of the corrosion protection we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler mate rials and the materials of the other heat ing system components Using antifreeze in boilers Viessmann boilers are designed and built for water as a heat transfer medium To protect boiler systems from frost it may be necessary to treat the boiler water or circulating water with anti freeze When doing so observe the following m In general follow the specifications given by the antifreeze manufacturer m The properties of antifreeze and water are very different m The temperature stability of the anti freeze must be sufficient for the par ticular application m Check the compatibility with sealing materials If other sealing materials are used take this into account when designing the system m Antifreeze developed especially for heating systems contains inhibitors and buffer substances for c
3. alkaline earths mol m lt 0 02 Total hardness in dH lt 0 11 The standard values assume the follow ing m The total volume of fill and top up water of the heating system during its service life will not exceed three times the water content of the heating sys tem m The specific system volume is less than 20 I kW heating output In multi boiler systems apply the output of the smallest boiler m All measures to prevent corrosion on the water side in accordance with VDI 2035 sheet 2 have been imple mented 24 Soften the fill and top up water in heating systems operating under the following conditions m The total of alkaline earths in the fill and top up water exceeds the stand ard value m Higher fill and top up water volumes are expected When designing the system observe the following m Install shut off valves in different sec tions This prevents the need to drain the entire heating water in case of repairs or system expansion m Install a water meter to record the amount of the fill and top up water Enter the volume of fill water and the water hardness into the boiler service instructions Operating information m Commission the system step by step starting with the lowest boiler output and a high heating water flow rate This prevents a localised concentra tion of limescale deposits on the boiler heating surfaces m During expansion or repair work only drain the absolutely necessary
4. neren 15 on ne 5 Opening the cleaning door and cleaning cover 16 6 Cleaning heating surfaces and flue gas collector 16 7 Checking all gaskets seals and packing cords on the flue gas side on ne 8 Cleaning the sight glass 16 on nen Ee 9 Checking thermal insulation components and gaskets r a a dete 17 oe en 10 Closing boiler doors nn rness rren rn nenene 18 on Een Es 11 Securing the cleaning door and cleaning cover 18 e 12 Fitting the burner rs nesrrrrrrnnsnee 19 13 Checking all water connections for tightness e 14 Checking the inspection port for tightness 19 15 Checking the water chamber for deposits 21 e e e 18 e 19 e e 20 e e 21 Checking the water level and system pressure Checking the safety and control equipment Checking the safety valve renee 21 Checking all water connections for leaks after the boiler has been filled eeeeeeeeeteeeeeeneeees 21 Checking the water quality eee 22 Checking the thermal insulation Checking the installation room ventilation Checking the flue pipe for tightness 11 Commissioning inspection maintenance Steps commissioning inspection and cont 12 Commissioning steps Inspection steps Maintenance steps Page 24 Adjusting the burner
5. prevention 27 Water treatment ee 28 Water with low salt content 25 33 89 GLE 9099 34 89 GLE 9095 35 36 Viessmann Werke GmbH amp Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Subject to technical modifications 5606 319 GB
6. the chimney The system user must provide suitable installations to safely drain such condensate Technical safety information Any damage to the boiler that could lead to risks requires an immediate boiler shutdown If the boiler or any vessels suffer large scale damage notify the installation service company immediately before carrying out any repairs Observe all technical safety instruc tions In the case of damage nothing should be altered before an inspection takes place unless it is to prevent further dam age or to rescue somebody The boiler house must only be entered by authorised personnel Always keep the boiler house clean well lit and free from all objects that do not belong there and that might impair the operation The use of any part of the system as a drying area is prohibited 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 relevant authorities in the country of installation During operation all required exits must be left unlocked and free from obstruc tions The operating personnel must log all events such as faults adjustments consumption of spare parts and repairs A log must be maintained of all regular readings of the control instruments Obvious signs at weld seams leaking damaged areas severe corrosion unusual characteristics of operating instruments and system components as well a
7. 1 3 10 12 12 00 1020 10 2 1630 16 3 4 11 84 14 00 880 8 8 1450 14 5 5 12 98 16 50 830 8 3 1630 16 3 To protect the system against dew point corrosion the full load must be set to the rated boiler heating output and must not be switched off during the summer months full load at constant standby The minimum boiler water temperature is 70 C Adjust the return temperature raising facility to at least to 50 C oil operation or 55 C gas operation 2 The last digit of the part number indicates the boiler size 3 With a maximum permissible combustion output 23 Water quality requirements Water quality requirements Heating systems with rated operating temperatures up to 100 C VDI 2035 Water used in heating systems must meet the chemical values in the Drinking Water Ordinance Germany If well water 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 the Directive VDI 2035 sheet 1 Prevention of damage in water heating installations Scale for mation in domestic hot water supply installations and water heating installa tions applies in Germany check local regulations with the following standard values For further information see the annotations to Directive VDI 2035 Total heating output in kW gt 600 Total of
8. 23 5606 319 GB Commissioning inspection maintenance Further details regarding the individual steps Commissioning the system 5606 319 GB the flue outlet is closed Details provided by the burner 9 Check that the dewatering line if manufacturer and regarding installed is correctly connected to accessories the condensate drain The condensate drain must be Open the boiler doors and check closed when not in use that the turbulators if installed are fully inserted into the hot gas flues 10 Open the shut off valves in the oil lines at the oil tank and filter or the Check that the installation room gas shut off valve ventilation is unobstructed 11 Switch ON the mains isolator the Fill the heating system with water switch for the equipment required and vent the system for the boiler system and burner ON OFF switch in this order Please note n Unsuitable water quality can Burner manufacturer s oper damage the boiler body ating instructions Fill and operate the heating system with water compliant 12 Start the boiler at a low heating out with the Water quality put max 30 and heat up to a requirements from temperature of approx 30 K below page 24 the operating temperature The condensate drains must be Note open and any condensate must be Record the fill volume and total correctly collected or drained hardness on page 22 13 After the required flow temperature Check the system pressure has been ac
9. Checking the safety valve D gt Manufacturer s details Checking all water connections for leaks after the boiler has been filled Replace the gaskets every time a con 2 Replace the gasket nection has been opened 3 Retighten all connections after com 1 Clean the sealing face missioning 21 Commissioning inspection maintenance Further details regarding the individual steps cont Checking the water quality Enter the amount of top up water and the total hardness of the boiler water into the table For water quality requirements see page 24 Fill Top up Meter Total Total hard pH Water treat Date wate water read water ness valu ment r ing volume e m m m ms Feed Boile Boile Medi Meter water r r um ing vol wate wate ume r r The total hardness must not exceed 0 02 mol m 0 11 dH The pH value should be between 9 0 and 10 5 22 5606 319 GB 5606 319 GB Commissioning inspection mainte Further details regarding the individual steps cont Adjusting the burner Do Burner manufacturer s details Adjust the highest fuel oil HEL or gas throughput of the burner to the rated heating output of the boiler nance Boiler Rated heating output Pressure drop on flue gas side size HEL Gas HEL Gas MW MW Pa mbar Pa mbar 1 7 13 8 00 980 9 8 1190 11 9 2 8 55 10 00 820 8 2 1310 13
10. L Galia nera 30 Commissioning service reports cence cents eeeneeeteeeeeeeneeeeenaeeseenaees 32 Keyword indeX igii LA nies I a eae aas Enana 33 5606 319 GB 5606 319 GB Operating information Information on operating with temperatures up to 100 C Only fill and operate boilers and heating systems with water compliant with the water quality requirements see chapter Water quality requirements The system must be commissioned by the Viessmann Industrieservice Berlin the system installer or a qualified person authorised by the installer as well as the relevant expert Record all actual values in a test report These must be confirmed by the instal ler the relevant expert and the system user Within 4 weeks of the combustion equip ment being commissioned the operator must notify the local flue gas inspector accordingly check local regulations We would recommend that you operate the boiler constantly at the required oper ating pressure and at a boiler water tem perature of 70 C Even if no heat is drawn off for a longer period of time it is still better to operate the boiler continu ously In systems comprising several boilers of which one is constantly used as a standby boiler only change operation over from one to another after longer intervals e g during the annual inspec tion of the entire system Operating instructions on pre serving the water and hot gas sides Inf
11. Operating and service VI EMAN N instructions for contractors Vitomax 200 HW Type M74A Oil gas high pressure hot water boiler Rated heating output 8 0 to 16 5 MW VITOMAX 200 HW 5606 319 GB 9 2011 Please keep safe Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate rial 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 envi ronmental pollution Note Details identified by the word Note con tain additional information Target group These instructions are exclusively designed for qualified contractors m Work on gas installations must only be carried out by a registered gas fitter m Work on electrical equipment must only be carried out by a qualified elec trician m The system must be commissioned by Viessmann Industrieservice the sys tem installer or a qualified person authorised by the installer Regulations Observe the following when working on this system m All legal instructions regarding the pre vention of accidents m All legal instructions regarding envi ronmental protection m Health and Safety at Work Act BetrSichV Germany m The Code of Practice of relevant trade associations m Directive 97 23 EC as well as the rel evant safety regulations of the follow ing countries DVGW TRGI T
12. RF and VDE TRD 4 KG ABV LRG K LRV K DKBG GH SEV SUVA SVGW SVTI SWKI VKF and EKAS Directive 1942 LPG part 2 If you notice oil leaks and the smell of gas A Danger Escaping fuel can lead to explo sions which may result in very serious injuries m Do not smoke Prevent naked flames and sparks Do not press any switches for lights or electrical appliances m Close the quick acting fuel valve and shut off valve m Open windows and doors m Remove all people from the danger zone m Notify your gas or electricity supply utility from outside the building m Shut off the electricity supply to the building from a safe place outside the building 5606 319 GB 5606 319 GB Safety instructions cont If you smell flue gas Danger Flue gas can lead to life threat ening poisoning m Shut down system m Ventilate boiler room Working on the system m Close the fuel shut off valve and secure against unintentional opening m Isolate the system from the power sup ply and check that it is no longer live e g by removing the separate fuse or by means of a main isolator m Safeguard the system against unau thorised reconnection I Please note n Electronic assemblies can be damaged by electrostatic dis charges Before beginning work touch earthed objects such as water pipes to discharge static loads Danger Risk of burning from hot surfaces so that m steam line m hot water lin
13. and the VdTUV datasheet 1466 regarding the water quality for hot water boilers in heat ing systems the following details apply to heating systems operated with flow temperatures in excess of 100 C Operation with circulating water with low salt content Only use water with low salt content as fill or top up water such as desalinated water permeate or condensate Systems using mixed condensate generally create water with low salt content if no boiler water is fed into the system for alkanization Operation with saline water Where possible use water with a low salt content that is at least free from alkaline earths softened as fill or top up water 25 Water quality requirements Water quality requirements cont Low salt content Saline El conductivity at 25 C uS cm 10 to 30 gt 30 to 100 gt 100 to 1500 General requirements clear without clear without clear without sediments sediments sediments pH value at 25 C 9 10 9 10 5 9 10 5 pH value according to the lt 9 5 lt 9 5 lt 9 5 Drinking Water Ordinance Drinking Water Treatment Ordinance or local regula tions Oxygen 02 mg lt 0 1 lt 0 05 lt 0 02 Values for constant oper litre ation are generally signifi cantly lower Alkaline earths Ca Mg mmol lt 0 02 lt 0 02 lt 0 02 litre Phosphate PO mg lt 5 lt 10 lt 15 litre Phosphate PO accord mg lt 7 lt f lt 7 ing to the Drinking Water
14. ater after some time in use indicates that free oxygen is no longer present The Technical Rules and in particular Directive VDI 2035 sheet 2 therefore rec ommend that heating systems are designed and operated so that a con stant ingress of oxygen into the heating water is prevented Opportunities for oxygen ingress during operation m Through open expansion vessels receiving a flow m Through negative pressure in the sys tem m Through gas permeable components Sealed unvented systems e g with dia phragm expansion vessel offer good protection against the ingress of airborne oxygen into the system if correctly sized and operated at the correct pressure At every part of the heating system even at the suction side of the pump and under all operating conditions the sys tem pressure should be above ambient atmospheric pressure The pre charge pressure of the dia phragm expansion vessel should be checked at least during the annual serv ice The use of permeable components e g plastic pipes that are permeable to gas in underfloor heating systems should be avoided Provide system separation if such components are nevertheless used This must separate the water flow ing through the plastic pipes from other heating circuits e g from the heat source by the provision of a heat exchanger made of corrosion resistant material No further anti corrosion measures are required for sealed unvented hot water
15. e m cleaning cover and closures plugs at the boiler system m boiler doors as well as compo nents behind the doors can all become very hot Observe safety in the workplace Safety instructions Repair work I Please note n Repairing components that fulfil a safety function can compromise the safe operation of your sys tem Replace faulty components only with original Viessmann spare parts Auxiliary components spare and wearing parts Please note n Spare and wearing parts that have not been tested together with the heating system can com promise its function Installing non authorised components and making non approved modifica tions or conversions can compro mise safety and may invalidate our warranty For replacements use only orig inal spare parts supplied or approved by Viessmann Draining hot water I Please note n The blow down and T D S water from boiler systems can reach temperatures of up to and over 100 C Set up the system in such a way that this water is cooled to a tem perature of lt 35 C before being channelled into the drainage sys tem If necessary consult the local water board Safety instructions Safety instructions cont Draining condensate from the flue gas side Please note a When starting up the boiler sys tem or under certain operating conditions condensate may build up in the flue passes the flue gas collector and the downstream flues including
16. ets approved in accord ance with TRD 401 appendix 1 or VdTUV or local regulations 19 Commissioning inspection maintenance Further details regarding the individual steps cont A T HA A ae A l AA A dl a A Caution hot surface Cleaning apertures Handhole Headhole 20 5606 319 GB 5606 319 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking the water chamber for deposits 1 Fully drain the boiler 2 Clean the water chamber hose it out and remove deposits via the drain In Danger case of harder deposits that cannot Heating water escaping under be removed by hosing down carry pressure will cause injury out chemical cleaning using an Only open connections and approved solvent inspection ports on the heat ing water and flue gas sides if 3 Clean the sealing faces of the hand the boiler has been depres hole and headhole covers and surised and cooled replace gaskets Retighten new gas kets after commissioning and check Please note again after 24 hours run a Draining the boiler with a suc tion pump will create negative pressure inside the boiler Only drain the boiler with a suction pump if the air vent valve is open Please note n Hot water can cause dam age Never drain hot water into the drainage system Ensure adequate cooling
17. he burner m Check the thermal insulation on the hot gas side i e on covers and doors Record the results of the daily monthly and bi annual checks in a log 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 of the period during which the boiler is taken out of use There is a differentiation between wet preservation during which exposure to oxygen is to be avoided and dry preservation during which moisture levels are to be minimised 5606 319 GB 5606 319 GB Shutdown cont Brief operational interruption 1 to 2 days Water side Recommendation Maintain the boiler pressure and temperature If this is not possible 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 binder than usual to the feedwater until the boiler is shut down Flue gas side Keep the heating surfaces dry Remove severe contamination as it binds mois ture See chapter Using antifreeze in boilers Operating information Longer interruptions of operation Water side Wet preservation if no risk of frost exists 1 Fill the boiler up to the highest possi ble level with treated feedwater To prevent oxygen corrosion add an oxygen binder to the boiler water e g sod
18. hieved open the boiler return valve the feedwater valve if Check all fitted components such required and then very slowly the as pipework valves controllers boiler flow valve pumps etc for function and leaks 14 Only then should the full burner load Check the fuel supply for leaks and be enabled pressure 15 While the system heats up check Open the flue gas damper if instal the correct function of all control and led safety equipment Check that the cleaning aperture on 16 Observe the pressure and temper ature test equipment 13 Commissioning inspection maintenance Further details regarding the individual steps cont 17 Check the fittings for leaks and retighten if required Closure Dimen Torque sions Hand 100 x 100 Nm hole 150 mm M 16 Head 220 x 200 Nm hole 320 mm M 20 Shutting down the system Danger Heating water escaping under pressure will cause injury Only open connections and inspection ports on the heating water and flue gas sides if the boiler has been depressurised and cooled Please note Draining the boiler with a suction pump will create negative pres sure inside the boiler Only drain the boiler with a suc tion pump if the air vent valve is open 14 18 After approx 50 hours run check the boiler doors and cleaning cover for leaks and retighten all screws torque approx 20 Nm Please note Hot water can cause damage Never drai
19. ium sulphite in accordance with the manufacturer s instructions Test the oxygen binder concentration at least monthly and top up if required For this ensure a good admixing with the boiler water thermal or mechani cal agitation 2 In multi boiler systems if only some boilers must be preserved these can be filled with desalinated boiler water from the boilers that remain in use This will also maintain the tempera ture 3 Maintaining pressure in a fully filled boiler using nitrogen preferably nitro gen 5 0 of 0 1 to 0 2 bar can prevent corrosion Dry preservation if there is a risk of frost or prolonged idle period Drain the boiler at 90 C and then open the water connections Dry the boiler thoroughly and fill with dessicant e g silica gel in accordance with the manufacturer s details Ensure that the dessicant does not come into contact with the boiler material Then close the boiler again Check in regular intervals whether the dessicant is still able to absorb moisture e 2 O e Operating information Shutdown cont Flue gas side Thoroughly clean and dry the surfaces on the flue gas side Maintain the alkaline balance of the wash water pH 8 9 in the case of ammonia pH 10 After thoroughly drying the surfaces pre serve them with a thin film of graphite or varnish Keep the surfaces dry during the idle periods by adding a dessicant such as silica gel or by air circu
20. lation via a con nected dryer Maintenance instructions We recommend having the boiler system serviced regularly to ensure fault free efficient and environmentally responsi ble operation The boiler should be cleaned regularly to prevent the flue gas temperature rising with increasing contamination which leads to higher energy consumption We recommend the installation of a flue gas thermometer Monitoring the flue gas temperature highlights incorrect burner adjustment and the level of boiler contamination Excessive flue gas temperatures through contamination or altered burner adjustment reduce efficiency Where necessary clean the boiler or adjust the burner settings 10 Further details For further details see the operating instructions for preservation on the water and hot gas side or the VdTUV data sheets no 1465 Oct 1978 and the VGB no R116H 1981 or local regula tions 5606 319 GB 5606 319 GB Commissioning inspection maintenance Steps commissioning inspection and maintenance For further information regarding the individual steps see the page indicated Commissioning steps Inspection steps E Maintenance steps Page on em 1 Commissioning the system 13 om Ne 2 Shutting down the system eerren eeen 14 3 Removing the burner if required 15 ee 4 Opening the boiler doori
21. litre Ordinance Drinking Water Treatment Ordinance Phosphate PO for mg lt 2 5 lt 5 lt 15 Viessmann hot water boil litre ers When using oxygen bind ers Sodium sulphite Na SO3 mg lt 10 When using other suitable litre products observe the rele vant guidelines issued by the respective supplier The VdTUV datasheet 1466 advises that further oxygen binders are offered as chemicals which may have the following active ingredients m Ascorbic acid m Carbohydrazide m Diethylhydroxylamine DEHA 4 The oxygen concentration in the circulating water may be up to 0 1 mg litre if suit able inorganic corrosion inhibitors are used 26 m Hydroquinone m Methyl ethyl ketoxime Meko m Tannin 5606 319 GB 5606 319 GB Water quality requirements Water quality requirements cont These must be used with care however as they can give rise to oxidation cleav age and transformation products under boiler operating conditions For further details please refer to the directive men tioned above Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous materials on the heating water side of heating systems and boilers depends on the absence of oxygen in the heating water The oxygen introduced into the heating system with the first filling and subse quent top ups reacts with the system materials without causing damage The characteristic blackening of the w
22. n hot water into the drainage system Ensure adequate cooling Shut down the burner Close the shut off valves in the oil lines at the oil tank and filter or the gas shut off valve Isolate the system from the power supply Close all valves 5606 319 GB 5606 319 GB Commissioning inspection maintenance Further details regarding the individual steps cont Removing the burner if required 1 Remove the fuel supply line For pressure jet gas burner Remove the gas supply pipe Danger Escaping gas leads to a risk of explosion Check all gas connections for tightness 2 Undo screws A and remove burner with burner plate 8 Undo screws A on boiler doors 8 and swing open boiler doors 15 Commissioning inspection maintenance Further details regarding the individual steps cont Opening the cleaning door and cleaning cover Undo nuts and remove cleaning cover 8 Open cleaning door 2 Cleaning heating surfaces and flue gas collector 1 Clean flues A combustion chamber and rear reversing chamber with suitable cleaning equipment and remove combustion residues 2 Remove combustion residues from the flue gas collector back Cleaning the sight glass Check sight glass with gaskets A for tightness and clean 16 5606 319 GB 5606 319 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking thermal ins
23. ntifreeze in boilers cont m Solder connections should preferably be made with Ag or Cu hard solder If liquids containing chlorides are used for soft soldering any deposits must be removed from the circuit afterwards through thorough flushing A higher chloride content in the heat transfer medium can cause corrosion damage m Only use oxygen diffusion resistant hoses or metal hoses for flexible con nections m Never equip the system on the primary side with zinc plated heat exchangers containers or pipes as zinc can be cor roded by glycol water mixtures m To avoid the risk of corrosion ensure that there is no difference in electrical potential between system compo nents that are in contact with anti freeze m Route all pipes in such a way that cir culation cannot be interrupted by gas cushions or deposits m The water circuit must always be filled up to the highest point with the heat transfer medium m After filling ensure there are no more air cushions in the system When the temperature falls gas cushions form negative pressure and this can draw air into the system m After initial filling and commissioning but after 14 days at the latest clean the integral dirt trap so the heat trans fer medium can flow freely m Following any losses through leaks or drawing off top up the antifreeze sol ution according to the concentration already in place Establish the volume of antifreeze as a check 29 Part
24. ormation Information on operating with temperatures in cont Operating checks Danger Boiler components that are not thermally insulated can be sub ject to high temperatures that can cause burns Take care with hot surfaces Subject to the safety equipment fitted and the details in the approval certificate either monitor the correct boiler opera tion constantly every 24 hours or every 72 hours Determine the extent of checks required in accordance with TRD 601 sh 1 sec tion 7 or local regulations Test the chemical composition of the boiler water and feedwater constantly in accordance with EN 12953 part 10 and VdTUV data sheet 1466 or local regulations Carry out the following checks daily or every 72 hours subject to boiler version and the manufacturer s specification see also TRD 601 sh 1 m Blow down the boiler only for boilers without automatic facility briefly open the valve two or three times at operat ing pressure m Check the water level limiter m Check the feedwater and boiler water Shutdown Carry out the following checks monthly m Check the function of the safety valve m Check the function of all control and safety equipment m Check all connections and fittings for tightness m Check the installation room ventila tion Have someone carry out the following checks every six months in accord ance with TRD 602 and 604 m Check the safety equipment m Check t
25. ormation on operating with temperatures in excess of 100 C According to the Pressure Equipment Directive 97 23 EC a boiler system to category IV may only be taken into use once the relevant authority has granted permission for the installation of the sys tem and the relevant expert has tested the system The system must be commissioned by the Viessmann Industrieservice Berlin the system installer or a qualified person authorised by the installer as well as the relevant expert Record all actual values in a test report These must be confirmed by the instal ler the relevant expert and the system user According to the Pressure Equipment Directive 97 23 EC hot water boilers to category IV may only be operated supervised and maintained by a trained boilerman The relevant authority may grant upon application permission to operate the boiler without constant supervision sub ject to it being equipped in accordance with EN 12953 part 6 In systems comprising several boilers of which one is constantly used as a standby boiler only change operation over from one to another after longer intervals e g during the annual inspec tion of the entire system We would recommend that you operate the boiler constantly at the required oper ating pressure and temperature Even if no heat is drawn off for a longer period of time it is still better to operate the boiler continuously e 2 a O e Operating inf
26. orrosion protection as well as glycol When using antifreeze always observe the manufacturer s instructions regarding minimum and maximum concentra tions 28 We recommend you refer questions of water treatment to Viessmann Industrie service or an appropriate specialist Further details can be found in Directive VDI 2035 sheet 2 and EN 14868 m The concentration must never fall below the prescribed minimum level subject to the required frost protection temperature Check and adjust the pH value and frost protection measure the density regularly at least once a year according to the manufacturer s instructions m Check with the relevant supplier whether antifreeze may affect system components that are not part of the boiler such as pumps electrically and pneumatically driven valves other types of valves gaskets etc m f the system is filled with antifreeze it must be marked accordingly m lf a boiler system is changed to oper ate without antifreeze flush the sys tem in order to remove all traces of the antifreeze m The quality of the boiler water and feedwater must meet the require ments of Directive VDI 2035 m The systems must be designed as sealed unvented systems as the anti freeze inhibitors decrease rapidly if air borne oxygen is allowed to enter m Diaphragm expansion vessels must comply with DIN 4807 or local regula tions 5606 319 GB 5606 319 GB Water quality requirements Using a
27. pipe work sections 5606 319 GB 5606 319 GB Water quality requirements Water quality requirements cont m Where water treatment is required treat even the first fill of the heating system prior to commissioning This also applies to any subsequent filling e g when adding top up water or after a repair or system expansion m Filters dirt traps and other blow down or separating facilities in the heating water circuit must be checked cleaned and activated more frequently after commissioning or recommission ing and later on as required subject to the water treatment applied e g water softening The build up of limescale deposits on the heating surfaces will be minimised if these instructions are observed Any limescale deposits that have formed because the requirements to Directive VDI 2035 have not been observed will in most cases already have caused a reduction in the service life of the instal led heating equipment Removing the limescale deposits is one option for restoring operational viability This measure must be carried out by the Viessmann Industrieservice or a special ist company Inspect the heating system for possible damage prior to returning it into use It is essential that the faulty operating parameters are corrected to prevent renewed formation of excessive scale deposits Heating systems with rated operating temperatures in excess of 100 C EN 12953 According to EN 12953 part 10
28. s lists Parts lists When ordering spare parts Quote the serial number and type as well as the quantity required Standard parts are available from your local supplier A corresponding amount of installation adhesive is provided Boiler size 1 2 3 4 5 Pos Component Number Number Number Number Number 1 Packing per boiler door 2 Packing per boiler door 3 Insulation ring 4 Burner connection packing 5 Cleaning cover pack ing 6 Rear boiler floor pack ing 7 Packing per cleaning aperture 8 Handhole gasket 100 x 150 mm 9 Seal ring set 10 Headhole gasket 225 x 325 mm Please order individual parts from Viessmann Industrieservice Tel 49 0 30 6602 389 Fax 49 0 30 6602 136 Email industrieservice viessmann com Internet www viessmann industriekessel de 2 The last digit of the part number indicates the boiler size 30 5606 319 GB 5606 319 GB Parts lists cont Parts lists 31 Commissioning service reports Commissioning service reports Commissioning Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by 32 5606 319 GB 5606 319 GB Keyword index A Alkaline earths total of
29. s unusual noise inside the boiler must be notified immediately Faults and defects on the system that cannot be remedied by experts locally must be noti fied to the manufacturer Protect all boiler parts and control equipment from rain water leaks and expelled steam Any damage or leaks that occur should be repaired without delay Apart from the relevant legal require ments all practical instructions issued by our technical personnel to the operating personnel are applicable 5606 319 GB 5606 319 GB Safety instructions Technical safety information cont Itis impossible to clarify and describe all potential cases of indicators and possi ble faults After the system has been operated for a certain time the regula tions specified should therefore be sup plemented in the light of experience gained Index Index Operating instructions Operating information Information on operating with temperatures up to 100 C eeeeeeeee 7 Information on operating with temperatures in excess of 100 C sita LT SNUJOW soeps e aea r aio we 8 Maintenance instructions 10 Service instructions Commissioning inspection maintenance Steps commissioning inspection and maintenance i 11 Further details regarding the individual StepS i 13 Water quality requirements Waterqualityreguirements accaiacni ia 24 Using antifreeze in bollefs uasilazaio ibi in een 28 Parts lists n pci iaia i
30. ulation components and gaskets Check thermal insulation components and gaskets 8 Replace faulty components 17 Commissioning inspection maintenance Further details regarding the individual steps cont Closing boiler doors 1 Close boiler doors 42 2 Tighten boiler door screws evenly torque approx 20 Nm Securing the cleaning door and cleaning cover 1 Secure both cleaning covers E so they seal tightly 2 Close cleaning door and secure it so it seals tightly 18 5606 319 GB 5606 319 GB Commissioning inspection maintenance Further details regarding the individual steps cont Fitting the burner 1 Fit burner plate 8 with screws A to burner flange 2 Seal annular gap if present between flame head and insulation rings with heat resistant insulation material see parts list 3 For pressure jet gas burner Fit the gas supply pipe A Danger Escaping gas leads to a risk of explosion Check all gas connections for tightness Checking the inspection port for tightness Danger Gasket manufacturer s installa Boiler components that are not tion instructions thermally insulated can be sub ject to high temperatures that can cause burns Take care with hot surfaces Note Replace the gaskets every time the con nections and inspection ports are opened Only use gask
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