Viessmann M22 Operating And Service Instructions Download

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Operating and service instructions

for contractors

Viesmann

Vitomax LW
Type M22
Type M62
Type M82

Low pressure hot water boiler

VITOMAX LW

6152553 GB

4/2020

Please keep safe.

Summary of Contents for M22

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

Page 2: ...erational Safety Ordinance BetrSichV and extended technical rules for operational safety TRBS Country specific safety regulations for the installation site National installation regulations Statutory regulations for the prevention of accidents Statutory regulations for environmental protection Codes of practice of the relevant trade associations Safety instructions for working on the system Commis...

Page 3: ...rts Please note Spare and wearing parts that have not been tested together with the system can compromise its func tion Installing non authorised com ponents and making non approved modifications or conversions can compromise safety and may invalid ate our warranty For replacements use only original spare parts supplied or approved by Viessmann Dismantling and disposal When dismantling and disposi...

Page 4: ... system allow it to cool to a temperature of 35 C If neces sary consult the local water board Draining condensate from the flue gas side Please note When starting up the boiler system or under certain operating condi tions condensate may form in the flue passes the flue gas collector and the downstream flues including the chimney This condensate must be drained away safely by means of suitable ins...

Page 5: ...he following Settings Readings Faults Replacement of spare parts Repairs Any defects must be dealt with immedi ately by trained personnel e g Abnormalities on weld seams Leaks Heavy corrosion Faulty instrument displays Noise in the boiler Faults and defects that cannot be rem edied locally must be reported to the manufacturer Protect all boiler parts and control equipment from rain water leaks and...

Page 6: ...eservation is for 15 Brief interruption in operation 3 days 15 Treatment on the water side 15 Treatment on the flue gas side 15 Interruption in operation 3 days 15 Treatment on the water side 15 Applicable regulations 16 Treatment on the flue gas side 16 6 Maintenance Information on maintenance 18 Preventing excessive flue gas temperatures 18 7 Commissioning inspec tion maintenance Steps commissio...

Page 7: ...g maintenance Not required during maintenance Note All diagrams in this document are schematic illustra tive examples Intended use The appliance is intended solely for installation and operation in sealed unvented heating systems with due attention paid to the associated installation serv ice and operating instructions The appliance is inten ded exclusively for steam generation and for heating wat...

Page 8: ...sible temperature water side 110 C Maximum permissible operating pressure 6 bar Boiler flow return temperature Maximum spread 50 K Maximum flue gas temperature 300 C Boiler with non condensing ECO Fuel Natural gas and EL fuel oil only for emergency operation Minimum water inlet temperature 65 C Maximum permissible temperature water side 150 C Maximum permissible operating pressure 16 bar Boiler fl...

Page 9: ... Fill and top up water Soften the water If the total of alkaline earths in the fill and top up water exceeds the standard value If larger fill and top up water volumes are expected Log the water volumes Install a water meter Enter the volume of water filled and the water hard ness in the boiler system operator s log Reduction of water consumption Install shut off valves in each section of the syst...

Page 10: ...te PO4 mg l 5 10 15 In accordance with the Drinking Water Ordi nance Drinking Water Treatment Ordinance mg l 7 7 7 For Viessmann hot water boilers mg l 2 5 5 15 Use of oxygen binders Sodium sulphite Na2SO3 3 mg l 10 Tab 2 Preventing water side corrosion General Oxygen is introduced into the heating system with the fill water when the system is filled initially and during any subsequent top ups Thi...

Page 11: ... the technical guide Operate the system with positive pressure In the entire boiler system On the pump suction side In every system operating state Additional protection against oxygen ingress Add an oxygen binder excess of 5 10 mg Na2SO3 l Adjust the pH value of the heating water to 8 2 9 5 Use of aluminium components Bear in mind that different conditions may apply Corrosion protection with chem...

Page 12: ...flue gas inspector where applicable should be notified of commissioning within 4 weeks Commissioning after boiler idle periods cold starts Cold start to EN 12953 3 Boiler start up from ambient pressure at room temper ature to normal operation full pressure cycle See engineering information for boiler cold warm start Please note A start up report must be filled in for each cold start For start up r...

Page 13: ...only as a substitute fuel for condensing and non condensing ECOs If using S fuel oil only use on site economisers that are suitable for this purpose Note For boiler types M62 and M82 without economiser If burning S fuel oil the average boiler water tempera ture must be at least 90 C according to DIN 51603 5 Boiler datasheet See chapter Standard values for water quality on page 9 Recommendation Do ...

Page 14: ...egulations Condensate from systems 200 kW must be neutral ised Condensate is treated by a neutralising agent in the neutralising system once it is discharged from the system The neutralising agent raises the pH value to between 6 5 and approx 9 Code of Practice DWA A 251 Condensate from condensing boilers Normal operation Notes on condensate drainage 6152553 Service ...

Page 15: ...uip ment thermal water treatment etc 3 days Select type of preservation Tab 5 Basic rule VdTÜV datasheet TC 1465 Preserving the water side of steam boilers Recommendation If using preservation methods that include chemicals other than those stated here please consult the chem ical manufacturers Brief interruption in operation 3 days Treatment on the water side Operating condition Measures The boil...

Page 16: ... a full boiler shell A fully filled boiler shell is maintained at a pressure of 0 1 to 0 2 bar using nitrogen specifically nitrogen 5 0 Please note Frost may cause damage to the boiler Do not use wet preservation if there is a risk of frost Please note Do not use layer forming monoamines The use of film forming polyamines must be agreed with and approved by the boiler manu facturer Recommendation ...

Page 17: ...e special installation conditions that prevail in these areas Detailed information Operating instructions for preservation on the water and hot gas side Datasheets of the VdTÜV no MB TECH 1466 dated 2014 01 and the VGB no R116H dated 2009 Notes on decommissioning and preservation Treatment on the flue gas side cont 6152553 Service ...

Page 18: ...act details see page 33 Other authorised contractors Preventing excessive flue gas temperatures Excessively high flue gas temperatures make the system less efficient Cause of fault Remedy Altered burner adjustment Adjust the burner correctly Contaminated boiler system Clean the boiler system Tab 7 Recommendation Constant monitoring of the flue gas temperature Maintenance Information on maintenance...

Page 19: ...askets 24 11 Inserting turbulators if installed and closing boiler door s 25 12 Closing and securing the inspection ports 25 13 Mounting the burner if required 26 14 Checking the water chamber for deposits M62 M82 27 15 Checking the connections and inspection ports on the water side for leaks 27 16 Checking the water level and system pressure 17 Checking the safety and control equipment 28 18 Chec...

Page 20: ...nd filter or open the gas shut off valve 14 Start the system in the following order Mains isolator Switches for all the equipment required for oper ating the boiler system ON OFF switch for the burner Operating instructions for the burner Burner operating and service instructions Please note Only adjust the burner at the end of these instructions 15 Start the system at a low heating output max 30 ...

Page 21: ...authority 1 Shut down the burner 2 Close the shut off valves in the oil lines at the tank and filter or the gas shut off valve 3 Isolate the system from the power supply 4 Close all valves Removing the burner if required A B Fig 1 1 Remove the fuel supply line 2 If necessary remove filler material 3 Undo screws A and remove the burner with burner plate B Please note The burner entry point or boile...

Page 22: ...e boiler door hinges Removing the inspection port closures Fig 3 Fig 4 1 Flue gas collector 1 Undo screws A from insulating fascia B and remove together with thermal insulation mat C 2 Undo screws D and remove cleaning cover E 2 Flame tube entry Remove screws F and pivot cleaning door G open 3 Remove nuts H and cover K Commissioning inspection maintenance Opening the boiler door s 6152553 ...

Page 23: ...s 2 Empty the flue gas collector at the back of the boiler Checking the gaskets and packing cords on the flue gas side Cleaning the sight glass A Fig 7 Clean the sight glass Check gaskets A Replace if necessary Danger Hot surfaces can cause burns Only open the slider in the sight glass for brief inspection of the flame Observe occupational safety Wear protective clothing where necessary Commission...

Page 24: ...24 A Fig 8 A Fig 9 Fig 10 Applies only to type M22 A Thermal insulation components B Gaskets Commissioning inspection maintenance Checking the thermal insulation components and gaskets 6152553 ...

Page 25: ... if necessary Inserting turbulators if installed and closing boiler door s B A Fig 12 1 Fully insert turbulators A into the 3rd flue Use tur bulator extractor B 2 Close the boiler door s 3 Tighten screws evenly to 20 Nm Closing and securing the inspection ports Fig 13 Commissioning inspection maintenance Checking the thermal insulation components and cont 6152553 ...

Page 26: ...l E 1 Fit burner plate B for the burner connection with screws A to the boiler flange 2 Secure the burner to the burner plate with screws Note For different dimensions trim the cut out in the thermal insulation according to the flame head diameter 3 If necessary fill annular gap between the burner head and thermal insulation with heat resistant filler material standard delivery Note Thermal insula...

Page 27: ... on page 21 Check again after 24 hours run Checking the connections and inspection ports on the water side for leaks Danger The surfaces of steam boilers and hot water boilers and other areas of the system are poten tially hot Risk of injury Always wear protective clothing when touching the relevant areas during operation 1 To check for leaks fill the boiler system with water 2 Check connections a...

Page 28: ...and control equipment Manufacturer s documentation for safety and control equipment Checking the safety valve Manufacturer s documentation for the safety valve Checking the water quality Document the top up volume and overall hardness of the boiler water See chapter Standard values for water quality on page 9 Checking the thermal insulation Checking the installation room ventilation Checking the f...

Page 29: ...urn temperature 80 60 C without economiser with condensing ECO 90 70 C with non condensing ECO Economiser water inlet temperature Condensing ECO 30 C Non condensing ECO 70 C Water flow rate Condensing ECO Continuous partial flow with a flow rate that equates to 30 of the max boiler water flow rate at a spread of 20 K Non condensing ECO Continuous full flow with a load dependent boiler water flow r...

Page 30: ...00 6 00 7 00 8 00 9 00 For EL fuel oil MW 2 30 2 80 3 50 4 20 5 00 6 00 7 00 8 00 9 00 Max pressure drop on the flue gas side with condensing ECO For natural gas mbar 8 7 10 7 11 8 12 6 14 3 15 7 17 3 11 8 13 4 Max pressure drop on the flue gas side with non condensing ECO For natural gas mbar 9 1 11 4 12 1 13 3 15 7 17 7 20 3 14 6 17 1 Max pressure drop on the flue gas side For natural gas mbar 7...

Page 31: ...dance with VdTÜV guideline Boiler has been taken out of service without being preserved too often Switch to standby instead of a complete shutdown Flue gas temperature is too high Heat transfer is reduced by contamination on the flue gas and water sides Clean the boiler The rated boiler heating output is exceeded Check burner heating output Discharge from safety valve The discharge pressure does n...

Page 32: ...5 Glass fibre reinforced fabric tape 6 Insulation rings 7 Glass fibre reinforced fabric tape 8 Gaskets Tab 12 Ordering information 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 5 The last digit of the part number indicates the boiler size Wearing parts Wear...

Page 33: ...ing aper ture closures 7 Cleaning cover packing 8 Rear boiler floor packing 9 Boiler door packing 10 Boiler door packing Tab 13 Ordering information 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 hotl...

Page 34: ...enance service Date By Maintenance service Maintenance service Maintenance service Date By Start up report The report can be used as a template Serial number Date Start time Please note Fill in and keep the report for each cold start in accordance with the engineering information Vitomax cold and warm starts in shell boilers Start up reports are a prerequisite for verifying the warranty Commission...

Page 35: ...ating up the consumer network Time Boiler flow tem perature Boiler re turn tem perature Water tempera ture ECO outlet Shunt pump load or position of shunt valve Combus tion heat ing output Flue gas tempera ture Comments h C C C kW C Burner load maximum 30 of the maximum re quired combustion heating output or low burner load Start 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 25 2 50 2 75 3 00 Com...

Page 36: ...er flow tem perature Boiler re turn tem perature Water tempera ture ECO outlet Shunt pump load or position of shunt valve Combus tion heat ing output Flue gas tempera ture Comments h C C C kW C Burner load up to 100 of the maximum required combustion heating output Commissioning service reports Start up report cont 6152553 Appendix ...

Page 37: ...ler flow tem perature Boiler re turn tem perature Water tempera ture ECO outlet Shunt pump load or position of shunt valve Combus tion heat ing output Flue gas tempera ture Comments h C C C kW C Burner load up to 100 of the maximum required combustion heating output Commissioning service reports Start up report cont 6152553 Appendix ...

Page 38: ...ces 23 I Inspection ports 22 25 Interruption in operation 15 Interruption of operations 5 L Limescale deposits 9 Low NOx burner 29 M Mixed condensation 10 Multi boiler system 9 13 N Nitrogen 16 O Operating conditions 13 Operating information 9 OWS for 72 hours 15 Oxygen corrosion 31 Oxygen ingress corrosion 11 16 P Preservation 15 Pressure drop on the flue gas side 29 R Report 5 S Safety valve 28 ...

Page 39: ...39 6152553 ...

Page 40: ...er Chaussee 3 D 15749 Mittenwalde Telephone 49 33764 83 0 Telefax 49 33764 83 202 www viessmann com Represented by Viessmann Ltd Hortonwood 30 TF1 7YP Telford Telephone 441952 675000 Telefax 441952 675040 www viessmann co uk 6152553 Subject to technical modifications ...

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