instructions Rated heating output 8.0 to 16.5 MW VIESMANN ...preserve the boiler surfaces on the...

Operating and serviceinstructionsfor contractors

VIESMANN

Vitomax 200-HWType M74AOil/gas high pressure hot water boilerRated heating output 8.0 to 16.5 MW

VITOMAX 200-HW

5606 319 GB 9/2011 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 informationInformation on operating with temperatures up to 100 °C.................................... 7Information on operating with temperatures in excess of 100 °C......................... 7Shutdown............................................................................................................. 8Maintenance instructions...................................................................................... 10

Service instructionsCommissioning, inspection, maintenanceSteps - commissioning, inspection and maintenance.......................................... 11Further details regarding the individual steps....................................................... 13

Water quality requirementsWater quality requirements.................................................................................. 24Using antifreeze in boilers.................................................................................... 28

Parts lists............................................................................................................ 30

Commissioning/service reports........................................................................ 32

Keyword index.................................................................................................... 33

Index

Index

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Only fill and operate boilers and heatingsystems with water compliant with thewater quality requirements (see chapter"Water quality requirements").The system must be commissioned bythe Viessmann Industrieservice, Berlin,the system installer or a qualified personauthorised by the installer as well as therelevant expert.Record all actual values in a test report.These must be confirmed by the instal-ler, the relevant expert and the systemuser.Within 4 weeks of the combustion equip-ment being commissioned, the operatormust notify the local flue gas inspectoraccordingly [check local regulations].

We would recommend that you operatethe boiler constantly at the required oper-ating pressure and at a boiler water tem-perature of 70 °C. Even if no heat isdrawn off for a longer period of time, it isstill better to operate the boiler continu-ously.In systems comprising several boilers, ofwhich one is constantly used as astandby boiler, only change operationover from one to another after longerintervals, e.g. during the annual inspec-tion of the entire system.

Operating instructions on pre-serving the water and hot gassides

Information on operating with temperatures in excess of 100 °C

According to the Pressure EquipmentDirective 97/23/EC, a boiler system tocategory IV may only be taken into useonce the relevant authority has grantedpermission for the installation of the sys-tem, and the relevant expert has testedthe system.The system must be commissioned bythe Viessmann Industrieservice, Berlin,the system installer or a qualified personauthorised by the installer as well as therelevant expert.Record all actual values in a test report.These must be confirmed by the instal-ler, the relevant expert and the systemuser.According to the Pressure EquipmentDirective 97/23/EC, hot water boilers tocategory IV may only be operated,supervised and maintained by a trainedboilerman.

The relevant authority may grant, uponapplication, permission to operate theboiler without constant supervision, sub-ject to it being equipped in accordancewith EN 12953 part 6.In systems comprising several boilers, ofwhich one is constantly used as astandby boiler, only change operationover from one to another after longerintervals, e.g. during the annual inspec-tion of the entire system.We would recommend that you operatethe boiler constantly at the required oper-ating pressure and temperature. Even if no heat is drawn off for a longerperiod of time, it is still better to operatethe boiler continuously.

Operating information

Information on operating with temperatures up to 100 °C56

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Operating checks

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

Subject to the safety equipment fittedand the details in the approval certificate,either monitor the correct boiler opera-tion constantly, every 24 hours or every72 hours.Determine the extent of checks requiredin accordance with TRD 601, sh. 1, sec-tion 7 [or local regulations]. Test thechemical composition of the boiler waterand feedwater constantly in accordancewith EN 12953 part 10 and VdTÜV data-sheet 1466 [or local regulations].Carry out the following checks daily orevery 72 hours, subject to boiler versionand the manufacturer's specification(see also TRD 601, sh. 1):■ Blow-down the boiler (only for boilers

without automatic facility; briefly openthe valve two or three times at operat-ing pressure).

■ Check the water level limiter.■ Check the feedwater and boiler water.

Carry out the following checksmonthly:■ Check the function of the safety valve.■ Check the function of all control and

safety equipment.■ Check all connections and fittings for

tightness.■ Check the installation room ventila-

tion.Have someone carry out the followingchecks every six months (in accord-ance with TRD 602 and 604):■ Check the safety equipment.■ Check the burner.■ Check the thermal insulation on the

hot gas side, i.e. on covers and doors.Record the results of the daily, monthlyand bi-annual checks in a log.

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).


Information on operating with temperatures in… (cont.)

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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.

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.

*1 See chapter "Using antifreeze in boilers"


Shutdown (cont.)

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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].

Maintenance instructions

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.


Shutdown (cont.)

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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........................................... 13

• • 2. Shutting down the system............................................. 14

• 3. Removing the burner (if required)................................. 15

• • 4. Opening the boiler door................................................. 15

• • 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 theflue gas side

• • 8. Cleaning the sight glass................................................ 16

• • • 9. Checking thermal insulation components andgaskets............................................................................ 17

• • • 10. Closing boiler doors....................................................... 18

• • • 11. Securing the cleaning door and cleaning cover.......... 18

• • 12. Fitting the burner............................................................ 19

• • 13. Checking all water connections for tightness

• • 14. Checking the inspection port for tightness................. 19

• 15. Checking the water chamber for deposits................... 21

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

• • • 17. Checking the safety and control equipment

• • • 18. Checking the safety valve.............................................. 21

• • 19. Checking all water connections for leaks after theboiler has been filled...................................................... 21

• • 20. Checking the water quality............................................ 22

• • 21. Checking the thermal insulation

• • • 22. Checking the installation room ventilation

• • • 23. Checking the flue pipe for tightness

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance56

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Commissioning steps

Inspection steps

Maintenance steps Page

• • 24. Adjusting the burner...................................................... 23


Steps - commissioning, inspection and… (cont.)

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Commissioning the system

Details provided by the burnermanufacturer and regardingaccessories

01. Open the boiler doors and checkthat the turbulators (if installed) arefully inserted into the hot gas flues.

02. Check that the installation roomventilation is unobstructed.

03. Fill the heating system with waterand vent the system.

! Please noteUnsuitable water quality candamage the boiler body.Fill and operate the heatingsystem with water compliantwith the "Water qualityrequirements" frompage 24.

NoteRecord the fill volume and totalhardness on page 22.

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 drain.The condensate drain must beclosed when not in use.

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

11. Switch ON the mains isolator, theswitch for the equipment requiredfor the boiler system and burner ON/OFF switch in this order.

Burner manufacturer's oper-ating instructions

12. Start the boiler at a low heating out-put (max. 30 %) and heat up to atemperature of approx. 30 K belowthe operating temperature.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 should the full burner loadbe enabled.

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 steps56

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17. Check the fittings for leaks andretighten if required.

Closure Dimen-sions

Torque

Hand-hole

100 x150 mm,M 16

100 Nm

Head-hole

220 x320 mm,M 20

200 Nm

18. After approx. 50 hours run, checkthe boiler doors and cleaning coverfor leaks and retighten all screws(torque approx. 20 Nm).

Shutting down the system

DangerHeating water escaping underpressure will cause injury.Only open connections andinspection ports on the heatingwater and flue gas sides 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.Check all gas connections fortightness.

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

Opening the boiler door

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



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Opening the cleaning door and cleaning cover

B

A

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

Cleaning heating surfaces and flue gas collector

A

B

1. Clean flues A, combustion chamberB and rear reversing chamber withsuitable cleaning equipment andremove combustion residues.

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

Cleaning the sight glass

Check sight glass with gaskets A fortightness and clean.



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Checking thermal insulation components and gaskets

A

Check thermal insulation componentsA and gaskets B.Replace faulty components.

BB

B

B

B

BB

AB

B



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Closing boiler doors

1. Close boiler doors A.

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

Securing the cleaning door and cleaning cover

B

A

1. Secure both cleaning covers B sothey seal tightly.

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



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Fitting the burner

A B C

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

2. Seal annular gap (if present) betweenflame 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.Check all gas connections fortightness.

Checking the inspection port for tightness

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 orVdTÜV [or local regulations].

Gasket manufacturer's installa-tion instructions



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A

C B C B B

C

C

Caution - hot surface!

A Cleaning aperturesB Headhole

C Handhole



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Checking the water chamber for deposits

1. Fully drain the boiler.

DangerHeating water escaping underpressure will cause injury.Only open connections andinspection ports on the heat-ing water and flue gas sides 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 solvent.

3. Clean the sealing faces of the hand-hole and headhole covers andreplace gaskets. Retighten new gas-kets after commissioning and checkagain after 24 hours 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 connections after com-missioning.



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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 24.

Fillwater

Top-upwater

Meterread-ing

Totalwatervolume

Total hard-ness

pHvalue

Water treat-ment

Date

m3 m3 m3 m3 Feed-

waterBoilerwater

Boilerwater

Medium

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 highest fuel oil (HEL) or gasthroughput of the burner to the ratedheating output of the boiler.

Boilersize*2

Rated heating output Pressure drop on flue gas sideHEL Gas HEL*3 GasMW MW Pa mbar Pa mbar

1 7.73 8.00 980 9.8 1190 11.92 8.55 10.00 820 8.2 1310 13.13 10.12 12.00 1020 10.2 1630 16.34 11.84 14.00 880 8.8 1450 14.55 12.98 16.50 830 8.3 1630 16.3

To protect the system against dew pointcorrosion, the full load must be set to therated boiler heating output and must notbe switched off during the summermonths (full load at constant standby).

The minimum boiler water temperatureis 70 ºC. Adjust the return temperatureraising facility to at least to 50 ºC (oiloperation) or 55 ºC (gas operation).

*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, the DirectiveVDI 2035 sheet 1 "Prevention of damagein water heating installations – Scale for-mation in domestic hot water supplyinstallations and water heating installa-tions" applies [in Germany; check localregulations] with the following standardvalues. For further information, see theannotations to Directive VDI 2035.

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

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

water of the heating system during itsservice life will not exceed three timesthe water content of the heating sys-tem

■ The specific system volume is lessthan 20 l/kW heating output. In multiboiler systems, apply the output of thesmallest boiler.

■ All measures to prevent corrosion onthe water side in accordance withVDI 2035 sheet 2 have been imple-mented.

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

and top-up water exceeds the stand-ard value.

■ Higher fill and top-up water volumesare expected.

When designing the system, observe thefollowing:■ Install shut-off valves in different sec-

tions. This prevents the need to drainthe entire heating water in case ofrepairs or system expansion.

■ Install a water meter to record theamount of the fill and top-up water.Enter the volume of fill water and thewater hardness into the boiler serviceinstructions.

Operating information:■ Commission the system step by step,

starting with the lowest boiler outputand 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 absolutely necessary pipe-work sections.

Water quality requirements


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■ Where water treatment is required,treat even the first fill of the heatingsystem prior to commissioning. Thisalso applies to any subsequent filling,e.g. when adding top-up water, or aftera repair or 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 DirectiveVDI 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.

Heating systems with rated operating temperatures in excess of100 °C (EN 12953)

According to EN 12953 part 10 and theVdTÜV datasheet 1466 regarding thewater quality for hot water boilers in heat-ing systems, the following details applyto heating systems operated with flowtemperatures 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 noboiler 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 alkalineearths (softened) as fill or top-up water.


Water quality requirements (cont.)

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Low salt content SalineEl. conductivity at 25 ºC μS/cm 10 to 30 >30 to 100 >100 to 1500General requirements clear, without

sedimentsclear, withoutsediments

clear, withoutsediments

pH value at 25 ºC 9 - 10 9 - 10.5 9 - 10.5pH value according to theDrinking Water Ordinance/Drinking Water TreatmentOrdinance [or local regula-tions]

≤9.5 ≤9.5 ≤9.5

Oxygen (O2)(Values for constant oper-ation are generally signifi-cantly lower)

mg/litre

< 0.1 < 0.05 < 0.02*4

Alkaline earths (Ca + Mg) mmol/litre

< 0.02 < 0.02 < 0.02

Phosphate (PO4) mg/litre

< 5 < 10 < 15

Phosphate (PO4) accord-ing to the Drinking WaterOrdinance/Drinking WaterTreatment Ordinance

mg/litre

≤7 ≤7 ≤7

Phosphate (PO4) forViessmann hot water boil-ers

mg/litre

< 2.5 < 5 < 15

When using oxygen bind-ers:

Sodium sulphite (Na2SO3)(When using other suitableproducts, observe the rele-vant guidelines issued bythe respective supplier)

mg/litre

– – < 10

The VdTÜV datasheet 1466 advises thatfurther oxygen binders are offered aschemicals, which may have the followingactive ingredients:■ Ascorbic acid■ Carbohydrazide■ Diethylhydroxylamine (DEHA)

■ Hydroquinone■ Methyl ethyl ketoxime (Meko)■ Tannin

*4 The oxygen concentration in the circulating water may be up to 0.1 mg/litre, if suit-able inorganic corrosion inhibitors are used.



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These must be used with care, however,as they can give rise to oxidation, cleav-age and transformation products underboiler operating conditions. For furtherdetails, please refer to the directive men-tioned above.

Prevention of damage due to 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 filling and subse-quent top-ups reacts with the systemmaterials without causing damage.The characteristic blackening of thewater after some time in use indicatesthat free oxygen is no longer present.The Technical Rules and in particularDirective VDI 2035 sheet 2 therefore rec-ommend that heating systems aredesigned and operated so that a con-stant ingress of oxygen into the heatingwater is prevented.

Opportunities for oxygen ingress duringoperation:■ Through open expansion vessels

receiving a flow.■ Through negative pressure in the sys-

tem.■ Through gas-permeable components.

Sealed unvented systems – e.g. with dia-phragm expansion vessel – offer goodprotection against the ingress of airborneoxygen into the system, if correctly sizedand operated at the correct pressure.

At every part of the heating system, evenat the suction side of the pump, andunder all operating conditions, the sys-tem pressure should be above ambientatmospheric pressure.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 heatsource – by the provision of a heatexchanger made of corrosion-resistantmaterial.No further anti-corrosion measures arerequired for sealed unvented hot waterheating systems subject to the abovepoints being 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 pH value of the heatingwater should be between 9.0-10.5.Different conditions apply to systemsthat contain aluminium components.



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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 Industrie-service or an appropriate specialist.Further details can be found in DirectiveVDI 2035 sheet 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 boilerwater or circulating water with anti-freeze.

When doing so, observe the following:■ In general, follow the specifications

given by the antifreeze manufacturer.■ The properties of antifreeze and water

are 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.

■ 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 water andfeedwater must meet the require-ments of Directive VDI 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 expansion vessels mustcomply with DIN 4807 [or local regula-tions].



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■ 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,containers 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:Quote the serial number and type, aswell as the quantity required.

Standard parts are available from yourlocal supplier. A corresponding amountof installation adhesive is provided.

Boiler size*2

1 2 3 4 5Pos. Component Number Number Number Number Number1 Packing per boiler

door

2 Packing per boilerdoor

3 Insulation ring 4 Burner connection

packing

5 Cleaning cover pack-ing

6 Rear boiler floor pack-ing

7 Packing per cleaningaperture

8 Handhole gasket100 x 150 mm

9 Seal ring set 10 Headhole gasket

225 x 325 mm

Please order individual parts from:Viessmann IndustrieserviceTel.: +49 (0)30/6602 389Fax.: +49 (0)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

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6

5

12

3

4

7

8 9 qP

8

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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AAlkaline earths, total of.......................13Anti-corrosion measures....................27

BBoiler door■ Opening..........................................15Boiler doors■ Closing............................................18Burner■ Adjusting.........................................23■ Fitting..............................................19■ Removal.........................................15

CChecking gaskets...............................17Checking the inspection port for tight-ness...................................................19Checking thermal insulation compo-nents..................................................17Checking the safety valve..................21Checking the water chamber for depos-its.......................................................21Checking the water quality...........22, 24Checking water connections..............21Chemicals for corrosion protection....28Cleaning cover■ Opening..........................................16■ Securing.........................................18Cleaning door■ Opening..........................................16■ Securing.........................................18Cleaning flue gas collector.................16Cleaning heating surfaces.................16Cleaning the sight glass.....................16

Commissioning....................................7Corrosion on the water side (preven-tion)....................................................27

DDiaphragm expansion vessel.............27

EExpansion vessel...............................27

FFill and top-up water....................22, 25

MMaintenance instructions...................10

OOperating checks.................................8

SSafety valve, checking.........................8Saline water.......................................25Shutdown.............................................8System■ Commissioning...............................13■ Shutting down.................................14

TTotal hardness of the boiler water......22

WWater side corrosion (prevention)......27Water treatment.................................28Water with low salt content................25

Keyword index

Keyword index56

06 3

19 G

B

34

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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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Transcript of instructions Rated heating output 8.0 to 16.5 MW VIESMANN ...preserve the boiler surfaces on the...