Viessmann Vitomax LW Operating And Service Instructions
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Viessmann Vitomax LW Operating And Service Instructions

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

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  • Page 1 Viesmann Operating and service instructions for contractors Vitomax LW Type M22 Type M62 Type M82 Low pressure hot water boiler VITOMAX LW Please keep safe. 6152553 GB 4/2020...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.

  • Page 3: Electrostatic Discharge

    Repairing components that fulfil a kets/seals on the gas side. safety function can compromise the safe operation of the system. Replace faulty components only with genuine Viessmann spare parts. Safety instructions for operating the system General The materials included in the product pose no threat to health during opera- tion.
  • Page 4 Safety instructions Safety instructions (cont.) If you notice oil leaks or smell gas Draining condensate from the flue gas side Danger Escaping fuel can lead to explo- Please note sions which may result in very seri- When starting up the boiler system, ous injuries.
  • Page 5 Safety instructions Safety instructions (cont.) Only authorised personnel are permitted Any defects must be dealt with immedi- to enter the boiler house. ately by trained personnel, e.g.: Keep the boiler house clean at all times. Abnormalities on weld seams ■ Do not store anything in the boiler Leaks ■...
  • Page 6 Steps - commissioning, inspection and maintenance ......19 tion, maintenance 8. Troubleshooting Diagnosis ....................31 9. Wearing parts Wearing parts and gaskets ..............32 Viessmann Industrial Service contact details ........33 ■ 10. Commissioning/service Reports for commissioning, inspection and maintenance ..... 34 reports Start-up report ..................34 Keyword index ........................

  • Page 7: Intended Use

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...
  • Page 8 Information Intended use (cont.) Intended use also includes: Boiler with non-condensing ECO ■ Use the specified equipment and auxiliary materials ■ Fuel: Natural gas and EL fuel oil (only for emergency (lubricants, spare and wearing parts, etc.). operation) ■ Equip for operation according to the country-specific ■...

  • Page 9: Standard Values For Water Quality

    Prolonged boiler service life Use a chemical water treatment system in the boiler ■ Reduced repair costs system. Request a quotation from Viessmann (for contact Advantages of using chemical water treatment details, see page 33). The specified standard values and water conditions ■...
  • Page 10 Water quality Standard values for water quality (cont.) Recommendation Commission Viessmann Industrial Service (for contact details, see page 33) or another contractor to carry out the relevant measures. Flow temperatures 100 °C (VdTÜV MB 1466) > Operating with circulating water with low salt con-...
  • Page 11 Water quality Standard values for water quality (cont.) Protecting the heating water from oxygen ingress Additional protection against oxygen ingress ■ Prevent continuous oxygen ingress and the entry of ■ Add an oxygen binder (excess of 5 - 10 mg airborne oxygen into the system during operation.
  • Page 12 Presence of a competent expert authority ■ Preparation of all necessary test reports; see 34 Authorised to commission the boiler: ■ Required signatories: Viessmann Industrial Service (for contact details, see System installer ■ – page 33) or Official expert authority –...

  • Page 13: Operating Conditions

    Normal operation Operating conditions Operating conditions Requirements/notes M62/M82 with- M62/M82 with M62/M82 with out econo- condensing non-condens- miser ing ECO Heating water flow rate No minimum heating water flow rate required Boiler return temperature (minimum value) Gas operation: 55 °C 55 °C 55 °C 65 °C...
  • Page 14 Normal operation Notes on condensate drainage During operation, acidic condensate forms in the boiler The neutralising agent raises the pH value to between and flue pipe. With gas combustion, the pH values are 6.5 and approx. 9. between 3 and 4. Drain off condensate in accordance with regulations.
  • Page 15 Notes on decommissioning and preservation Decommissioning Decommissioning means shutting down the system via A short-term shutdown is not recommended, as every the circuit breaker at the control panel. The duration of start-up process subjects the boiler to additional the shutdown determines the preservation measures stresses.

  • Page 16: Applicable Regulations

    Notes on decommissioning and preservation Interruption in operation 3 days > (cont.) Application: 3. Check the concentration of the oxygen binder reg- ularly and at least once a month; if necessary, add 1. Drain the hot water boiler (boiler including econo- more oxygen binder.
  • Page 17 Notes on decommissioning and preservation Treatment on the flue gas side (cont.) Recommendation for areas with high relative Detailed information humidity ■ Operating instructions for preservation on the Do not use dry preservation in areas with high relative water and hot gas side humidity due to the special installation conditions that ■...
  • Page 18 ■ Observe the specified maintenance intervals ■ Only use authorised companies: – Viessmann Industrial Service (for contact details, see page 33) Other authorised contractors – Preventing excessive flue gas temperatures Excessively high flue gas temperatures make the system less efficient...
  • Page 19 Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • • 1. Commissioning the system....................20 • • 2. Shutting down the system....................21 • 3. Removing the burner (if required)..................21 •...
  • Page 20 Commissioning, inspection, maintenance Commissioning the system Note 14. Start the system in the following order: Take notes for the reports during the process. Fill in ■ Mains isolator the start-up reports. ■ Switches for all the equipment required for oper- For start-up reports, see page 34 ating the boiler system ■...

  • Page 21: Commissioning The System

    Commissioning, inspection, maintenance Commissioning the system (cont.) Torque settings M Closure Dimensions Handhole 100 x 150 mm M16 100 Nm Headhole 220 x 320 mm M20 200 Nm Manhole 320 x 420 mm M24 350 Nm Tab. 8 Shutting down the system Danger Risk of injury when opening pressurised boiler flue connections.
  • Page 22 Commissioning, inspection, maintenance Opening the boiler door(s) Undo screws and open boiler door(s) Note There are versions of the boiler door that are designed to be hinged on the right or left. Boiler installation instructions – moving the boiler door hinges Fig.
  • Page 23 Commissioning, inspection, maintenance Removing and cleaning the turbulators (if installed) 1. Without using force, remove turbulators with turbulator extractor 2. Clean the turbulators. Fig. 5 Cleaning the heating surfaces and flue gas collector 1. Clean flues , combustion chamber and rear reversing chamber.
  • Page 24 Commissioning, inspection, maintenance Checking the thermal insulation components and gaskets Fig. 8 Fig. 9 Fig. 10 Applies only to type M22 Thermal insulation components Gaskets...
  • Page 25 Commissioning, inspection, maintenance Checking the thermal insulation components and… (cont.) Fig. 11 Applies only to type M62 and M82 Thermal insulation components Gaskets Check the thermal insulation components and gaskets. Replace if necessary. Inserting turbulators (if installed) and closing boiler door(s) 1.
  • Page 26 Commissioning, inspection, maintenance Closing and securing the inspection ports (cont.) Fit in reverse order to the description on page 22 "Removing the inspection port closures". Torque approx. 20 Nm. Fig. 14 Mounting the burner (if required) Danger Installation information on insulating the burner Risk of explosion from escaping gas.
  • Page 27 Commissioning, inspection, maintenance Mounting the burner (if required) (cont.) 5. Close the boiler doors and inspection port at the back of the boiler. Checking the water chamber for deposits (M62, M82) 1. Fully drain the boiler. 3. Clean the sealing faces and thread of the inspec- tion port.
  • Page 28 Commissioning, inspection, maintenance Checking the connections and inspection ports… (cont.) Note If the optional thermal insulation is fitted, this must first be removed. Fig. 19 Caution - hot surface! Headhole Inspection ports Manhole Handhole Note If the optional thermal insulation is fitted, this must first be removed. Checking the water level and system pressure Checking the safety and control equipment Manufacturer's documentation for safety and...

  • Page 29: Adjusting The Burner

    Commissioning, inspection, maintenance Adjusting the burner The combustion heating output of the burner must not Engineering information – Vitomax cold and exceed the permissible combustion heating output of warm starts in shell boilers the boiler. Do not set the maximum gas or oil through- put of the burner until the boiler has heated up to the Burner operating and service instructions rated boiler heating output.
  • Page 30 Commissioning, inspection, maintenance Adjusting the burner (cont.) Boiler size For natural gas mbar 11.6 12.4 13.6 16.0 18.1 20.8 15.1 17.6 ■ Max. pressure drop on the flue gas side For natural gas mbar 11.5 12.1 13.9 15.4 16.7 11.7 13.0 ■...

  • Page 31: Troubleshooting

    Troubleshooting Diagnosis Fault/system char- Cause of fault Measure acteristics Burner does not start. No voltage present. Switch on the mains isolator. Safety chain activated. Check safety equipment. Burner fault indicator illuminates. Press reset button on the burner control unit. Fuel supply is interrupted. Check shut-off valves in the fuel supply line and filter for obstructions.
  • Page 32 Wearing parts Wearing parts and gaskets Fig. 20 Illustration applies to M22 Order form for type M22 Serial number: Boiler size Pos. Component Quantity Packing per boiler door Packing per boiler door Upper insulation blocks Lower insulation blocks Glass fibre-reinforced fabric tape Insulation rings Glass fibre-reinforced...

  • Page 33: Wearing Parts

    Enter the serial no., type and amount required. Obtain commercially available parts from your local trade supplier. Note A suitable amount of installation adhesive for the packings is provided. Viessmann Industrial Service contact details 24/7 service hotline: +49 180 384 3776 Email: industrialservice@viessmann.com...

  • Page 34: Start-Up Report

    Commissioning/service reports Reports for commissioning, inspection and maintenance Note The reports can be used as templates. Commissioning Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Start-up report The report can be used as a template. Serial number Date Start time...

  • Page 35: Commissioning/Service Reports

    Commissioning/service reports Start-up report (cont.) Engineering information "Vitomax cold and warm starts in shell boilers" Note Prevent unnecessarily high mechanical stress and condensate formation in the flue gas during a cold start. Wait until the boiler has reached normal operating conditions before slowly heating up the consumer network. Shunt Water pump –...
  • Page 36 Commissioning/service reports Start-up report (cont.) Once the warm standby state has been reached (see cold and warm starts for shell boilers), record information every 0.5 h. Shunt Water pump – Boiler Boiler re- Combus- Flue gas tempera- load or Time flow tem- turn tem- tion heat-...
  • Page 37 Commissioning/service reports Start-up report (cont.) Once normal operating conditions have been reached and heat-up of the network has started, record information every 0.5 h. Shunt Water pump – Boiler Boiler re- Combus- Flue gas tempera- load or Time flow tem- turn tem- tion heat- tempera-...
  • Page 38 Keyword index Keyword index Alkalisation..............10 Mixed condensation........... 10 Ammonia..............16 Multi boiler system..........9, 13 Boiler water............ 10, 11, 28 Nitrogen..............16 Burner............21, 26, 29 Operating conditions..........13 Calcium carbonate............9 Operating information...........9 Cold starts..............12 OWS for 72 hours............15 Commissioning............12 Oxygen corrosion............
  • Page 40 Represented by Manufacturer Viessmann Ltd Viessmann Industriekessel Mittenwalde GmbH Hortonwood 30 Berliner Chaussee 3 TF1 7YP Telford D-15749 Mittenwalde Telephone: +441952 675000 Telephone: +49 33764 83-0 Telefax: +441952 675040 Telefax: +49 33764 83-202 www.viessmann.co.uk www.viessmann.com...

This manual is also suitable for:

M22M62M82M22aM62dM82b

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