Viessmann KRT 150 series, KRT 540 series, Vitoflex 300-RF series Service Manual

Service and
Maintenance Instructions

for use by engineers and heating contractors

KRT 150 to KRT 540 Series

Wood-fired Boiler
Max. output: 150 to 540 kW / 512 to 1843 MBH
Min. output: 45 to 140 kW / 154 to 478 MBH

Pyrot

r

WARNING

If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.

Do not store or use gasoline or other
flammable fluids in the vicinity of this or
any other appliance.

WHAT TO DO IF YOU SMELL FLUE GAS

 Deactivate heating equipment
 Open windows and doors.
 Inform your heating contractor

WARNING

Improper installation, adjustment and/or
operation could cause carbon monoxide
poisoning resulting in injury or loss of life.
This product must be installed and serviced
by a professional service technician who is
experienced and qualified in hot water boiler
installation and wood fuel combustion.

H

5603 880 - 01 12/2014

Product may not be exactly as shown

IMPORTANT

Read and save these instructions
for future reference

.

Please file in Service Binder

Introduction

Pyrot Service & Maintenance

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing service and/or maintenance. Failure
to comply with the instructions listed below and details printed in this manual can cause product/property damage,
severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed
information found in manual subsections).

Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.

For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.

Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.

Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.

Please see section entitled
“Important Regulatory and Installation
Requirements”.

Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to Viessmann equipment.

For a listing of chemicals which
cannot be stored in or near the
boiler room, please see subsection
entitled “Mechanical Room”.

Carbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.

For information pertaining to the proper
installation, adjustment, service and
maintenance of this equipment to avoid
formation of carbon monoxide, refer to
the installation and operating instructions.

Fresh air
This equipment requires fresh air for

safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.

For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Combustion Air Supply”.

Equipment venting
Never operate the boiler without an installed venting

system. An improper venting system can cause
carbon monoxide poisoning.

For information pertaining to
venting and chimney requirements,
refer to the installation and operating
instructions. All products of
combustion must be safely vented
to the outdoors.

Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service.

2

WARNING

Installers must follow local regulations with respect
to installation of carbon monoxide detectors. Follow
manufacturer’s maintenance schedule of the boiler
contained in the section “Cleaning and Maintenance”.

5603 880 - 01

Pyrot Service & Maintenance

About these Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important
product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

Indicates an imminently hazardous situation which,

WARNING

Warnings draw your attention to the presence of potential
hazards or important product information.

CAUTION

Cautions draw your attention to the presence of potential
hazards or important product information.

IMPORTANT

if not avoided, could result in death, serious injury
or substantial product/property damage.

Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.

Helpful hints for installation, operation or maintenance
which pertain to the product.

Introduction



Note: Viessmann Manufacturing Company Inc. reserves
the right to make product changes or updates
without notice and will not be held liable for
errors or omissions in the product literature.

This symbol indicates to note additional information

This symbol indicates that other instructions must be

referenced.

5603 880 - 01

3

Table of Contents

Pyrot Service & Maintenance

Page

Introduction

General Information

Safety

Maintenance

Safety, Installation and Warranty Requirements..............2

About these Instructions..............................................3

Product Information.....................................................5

Important Regulatory and Installation Requirements ........6

Safety Instructions......................................................8

Carbon Monoxide........................................................9

Extreme Weather Conditions......................................10

Hazardous Material....................................................11

Mechanical Room.....................................................12

Combustion Air Supply..............................................13

Components of the Biomass Boiler..............................14

Cleaning..................................................................15

Boiler.................................................................15

Heat exchanger displacement rods........................16

Installing the displacement rods.............................16

Removing the displacement rods...........................16

Flue gas cyclone (optional)....................................17

Pneumatic cleaning system (optional)...................17

Feed systems...........................................................18

Shutdown...............................................................19

Boiler..................................................................19

Extraction and conveyance systems.......................19

Control system....................................................19

Replacing the buffer battery..................................19

Ash disposal........................................................19

Disposal of the boiler............................................19

Instructions regarding removal...............................19

Waste disposal....................................................19

Troubleshooting

Performance Problems...............................................20

Grate Drive Mechanics Jams.....................................21

Checking for increased Wear of Fireclay......................22

Checking the Inside of the Boiler Door.........................23

Checking
Balancing the Oxygen

Heating System Faults..............................................26

Loader System Faults................................................27

the Oxygen Control System.........................24

Sensor.....................................25

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Pyrot Service & Maintenance

Product Information

General Information

Viessmann solid-fuel boiler can only be installed and
serviced by qualified trained personnel.

Steel wood-fired hot water heating boiler.

For operation primarily with modulating boiler water
temperatures in closed loop forced circulation hot water
heating systems. Under certain conditions, open loop
systems may also be considered. Contact Viessmann
for details.

Maximum allowable working pressure (water)…30 or 60 psi

Maximum water temperature…250°F (120°C) (closed loop)

Maximum boiler temperature……210°F (99°C) (open loop)

This boiler does not require a flow switch.

WARNING

Exposing the boiler to pressures and temperatures in
excess of those listed will result in damages and will
render the warranty null and void.

Codes

CSA B366.1-M91
Solid Fuel Fired Central Heating Appliances

CSA C.22.2#3-M88 (R2004)
Electrical Features of Fuel Burning Equipment

UL2523
Solid Fuel-Fired Hydronic Heating Appliances, Water
Heaters and Boilers

CSA B365-10
Installation Code for Solid Fuel Burning Appliances
and Equipment

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5

General Information

Important Regulatory and Installation Requirements

Please carefully read this manual prior to attempting
service and maintenance. Any warranty is null and void
if these instructions are not followed.

For information regarding other Viessmann System
Technology componentry, please reference documentation
of the respective product.

We offer frequent installation and service seminars to
familiarize our partners with our products. Please inquire.

Pyrot Service & Maintenance

Working on the equipment

The installation, adjustment, service, and maintenance
of this boiler must be done by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water boilers.

Ensure main power supply to equipment, the heating
system, and all external controls have been deactivated.
Take precautions to avoid accidental activation of power
during service work.

CAUTION

RISK OF INJURY: Shut the system off before starting
any cleaning. Be absolutely sure to wear protective
gloves, protective eyewear if required and use the
cleaning tools that come with the system (danger of
blow-ups, burns and getting crushed)!

Technical literature

Literature applicable to all aspects of the Pyrot wood-fired
boiler:

- Installation and Operating Instructions

- Service and Maintenance Instructions

- Field Wiring Diagram

The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. These include low-water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.

Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies.

This product comes with several safety instruction
labels attached.
Do not remove!
Contact Viessmann immediately if replacement labels
are required.

6

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Pyrot Service & Maintenance

Important Regulatory and Installation Requirements (continued)

Regular maintenance and service

The entire heating system must be cleaned and serviced
on a regular basis by a qualified contractor or service
agency to ensure reliable, energy-efficient, and
environmentally friendly operation.

The build-up of soot on the heat exchanger raises the
flue gas temperature and reduces efficiency.

WARNING

Improper installation, adjustment, service or maintenance
can cause flue products to flow into living space. Flue
products contain poisonous carbon monoxide gas, which
can cause nausea or asphyxiation resulting in severe
personal injury or loss of life.

General Information

WARNING

The boiler must not be located in areas or rooms where
chemicals are stored or aggressive vapors from (i.e.
bleach, hair spray, methyl chloride, carbon tetrachloride
or perchloroethylene) or high dust levels or humidity
levels are present. Heat exchanger corrosion might
occur and reduce the lifetime of the boiler significantly.
If above criteria are not properly observed and boiler
damage results, any warranty on the complete boiler
and related components will be null and void.

IMPORTANT

Keep boiler and boiler room clear and free of combustible
materials, gasoline and other flammable vapors and
liquids. Do not obstruct the flow of combustion and
ventilation air. All inspection, maintenance and service
must be performed by a qualified heating contractor.

WARNING

Service and maintenance can only be performed by a
qualified heating contractor.

Important to know

Do not use this boiler if any part has been under, or
exposed to, water. Immediately call a qualified heating
contractor to inspect the boiler and to replace any
part of the control system, which has been under or
exposed to water.

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7

Safety

Safety Instructions

Pyrot Service & Maintenance

IMPORTANT

The local building codes and regulations must be followed
by the heating contractor.

IMPORTANT

Please refer to the Installation and Operating
Instructions for installation, commissioning
and technical specification information. The
“Installation and Operating Instructions” contain
the necessary safety and national/local code
requirements which, if not followed exactly,
may lead to property damage, personal injuries
and/or death.

Important Information

Safety instructions

When carrying out work on the heating system, such as
cleaning and maintenance, wear appropriate protective
equipment when required.

There is a danger of getting injured through: burning,
knocking against corners and edges, crushing in moving
parts and noise.

Power supply: 120V or 240V/1/ and 208V/3/ 60Hz
In case of an emergency, the Pyrot can be disconnected
from the electrical power supply at all the leads by the
main switch on the control cabinet.

If you notice fire coming from the appliance, call the fire
department immediately!
DO NOT attempt to extinguish the fire unless qualified to
do so.

Doors: for safety keep firing and ash pit doors tightly closed

CAUTION

FIRE HAZARD:
The boiler must NEVER be operated with the doors open!
Any burning bits that escape could start a fire.

RISK OF INJURY:
If the doors are open during operation, sparks or flames
could leap out.

Equipment for dissipating excess heat: a competent
specialist should examine the operational reliability of
the thermal safety flush valve annually. The safety
heat exchanger must not by any means be used as an
operational heat exchanger.

Seals: for the functioning and controllability of the boiler,
it is important that no unwanted air can enter unchecked
through leaks.

The doors and lids have to shut tight - any damaged
seals must be replaced immediately. Tighten the retaining
screws and handles well.

Operation, cleaning and maintenance: bear in mind that
even the best product can only fulfill its functions well,
doing so for a long time and free of malfunctions, if
operated and maintained properly.

IMPORTANT

Compliance with the “Cleaning” section is mandatory!

WARNING

Fire causes a risk of burns and explosion!

 Shut down the boiler
 Close fuel shut-off valves
 Use a tested fire extinguisher, class ABC.

8

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Pyrot Service & Maintenance

Carbon Monoxide

Carbon monoxide

The U.S. Consumer Product Safety Commission strongly
recommends the installation of carbon monoxide detectors
in buildings in which wood-burning equipment is installed.
Carbon monoxide (CO) is a colorless, odorless gas, which
may be produced during incomplete combustion of fuel
and/or when the flame does not receive an adequate
supply of combustion air. Carbon monoxide can cause
severe personal injury or loss of life.

Therefore, carbon monoxide detectors that are in
compliance with a nationally recognized standard
(e.g. ANSI/UL 2034-2002, CSA 6.19-01) should be
installed and maintained in buildings that contain
wood-burning equipment.

Note: Viessmann does not test any detectors and makes
no representation regarding any brand or type of
detector.

Safety

Service/inspection of the boiler and the system must be
performed on a regular basis. Maintenance, service and
cleaning are specified in the section “Maintenance”.

Before the heating season begins, it is recommended that
the boiler be serviced by a qualified heating contractor.

WARNING

Improper installation, adjustment, service or maintenance
can cause flue products to flow into living space. Flue
products contain poisonous carbon monoxide gas, which
can cause nausea or asphyxiation resulting in severe
personal injury or loss of life.

WARNING

For safe operation

We recommend that you frequently:

- Check for debris which could obstruct the flow of
flue gases. The vent or chimney must not be blocked.
A blocked or partially blocked vent or
chimney can cause flue gases to leak into the
structure. Flue gases leaking into the house can
cause injury or death. Blocked or partially blocked
chimneys must have the blockage removed by a
qualified heating contractor.

- Check pressure gage for correct system (water)
pressure. Check for water on the floor from the
discharge pipe of the pressure relief valve or any
other pipe, pipe joint, valve or air vent.

- Check for moisture, water, or appearance of rust
on the flue gas pipes, their joints as well as vent
dampers, or side wall vent terminals (if so equipped).

- Ensure that nothing is obstructing the flow of
combustion and ventilation air and no chemicals,
garbage, gasoline, combustible materials, flammable
vapors and liquids are stored (not even temporarily)
in the vicinity of the boiler.

- DO NOT allow unsupervised children near the boiler.

The operator/ultimate owner is required to have the heating
boiler and controls checked, as a minimum once per year,
by the original installer or by a competent heating
contractor familiar with the equipment. Defects must
be corrected immediately.

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9

Safety

Extreme Weather Conditions

Frozen water pipe hazard

Your heating boiler is designed to provide a warm and
comfortable living environment. It is NOT designed to
ensure against freezing of water pipes. The boiler is
equipped with several safety devices that are designed
to shut down the boiler and to prevent it from
restarting in the event of various unsafe conditions.

Pyrot Service & Maintenance

If the building will be unattended for an extended period
of time during cold weather, you should...

Shut off the water supply to the building, drain the water
pipes and add antifreeze for potable water to drain traps
and toilet tanks. Open faucets where appropriate.

If your boiler remains off for an extended period of time
during cold weather, water pipes may freeze and burst,
resulting in extensive water damage and conditions in
which mold could grow. Certain molds are known to
cause respiratory problems, as well as to pose other
serious health risks. In case of water damage, immediate
measures should be taken to dry out affected areas as
quickly as possible to prevent mold from developing.

WARNING

As there are no user-serviceable parts on the boiler,
or control, the end-user must not perform service
activities of any kind on system components. Failure
to heed this warning can cause property damage,
severe personal injury or loss of life.

or…

Have someone check the building frequently during cold
weather and call a qualified service agency if required.

or...

Install a reliable remote temperature sensor that will notify
somebody of freezing conditions within the building.

10

5603 880 - 01

Pyrot Service & Maintenance

Hazardous Material

Fiberglass wool and ceramic fiber materials

WARNING

Inhaling of fiberglass wool and/or ceramic fiber materials
is a possible cancer hazard. These materials can also
cause respiratory, skin and eye irritation.

The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.

WARNING

Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are known
to the State of California to cause cancer, birth defects
and other reproductive harm. Always use proper safety
clothing, respirators and equipment when servicing or
working nearby the appliance.

First aid measures

- If eye contact occurs, flush eyes with water to
remove dust. If symptoms persist, seek medical
attention.

- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.

Safety

Suppliers of ceramic fiber products recommend the
following first aid measures:

- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.

- Eye irritation: If eyes become irritated, flush
immediately with large amounts of lukewarm water
for at least 15 minutes. Eyelids should be held away
from the eyeball to ensure thorough rinsing.
Do not rub eyes.

- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and water.
Using a skin cream or lotion after washing may be
helpful.

- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.

Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:

- Avoid breathing fiberglass dust and contact with
skin and eyes.

- Use NIOSH approved dust/mist respirator.

- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.

- Wash work clothes separately from other clothing.
Rinse washer thoroughly.

- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.

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11

Safety

Mechanical Room

Pyrot Service & Maintenance

No combustible materials may be stored in the heating
room. The heating boiler may only be set up on a fire­resistant and temperature-resistant floor. No temperature­sensitive pipes or lines may be installed in the floor
beneath the heating boiler.

A sufficient supply of fresh air must be provided directly
from outdoors into the heating room. Induced ventilation
is necessary for heating rooms that are confined or
enclosed.

See “Installation and Operating Instructions” for more
details.

The temperature in the heating room must not exceed
104°F (40°C) while the system is in operation
(in the area approx. 3 ft. (1 m) away from the boiler).
The temperature in the heating room must not fall below
50°F (10°C) while the system is in operation (measured
at the inner side of exterior walls).

IMPORTANT

Always follow the most up-to-date local, municipal and
building regulations and codes.

Mechanical room conditions

WARNING

Incorrect ambient conditions can lead to damage to
the heating system and put safe operation at risk.

Prevent the air from becoming contaminated by
homogenate hydrocarbons (e.g. as contained in paints
solvents or cleaning fluids) and excessive dust (e.g.
through grinding or polishing work). Combustion air for
the heating process, and ventilation of the boiler room
must be free of corrosive contaminants. To that end, any
boiler must be installed in an area that has no chemical
exposure. The list to the right indicates the main,
currently known sources.

Avoid continuously high levels of humidity (e.g. through
frequent drying of laundry).

Never close existing ventilation openings.

IMPORTANT

Components which are not tested with the heating
system may damage the heating system or affect its
functions. Installation or replacement may only be
carried out by a qualified heating contractor.

Sources of combustion and ventilation air contaminants

Areas likely to contain contaminants:

- New building construction

- Swimming pools

- Remodeling areas, hobby rooms

- Garages with workshops

- Furniture refinishing areas

- Dry cleaning/laundry areas and establishments

- Auto body shops

- Refrigeration repair shops

- Metal fabrication plants

- Plastic manufacturing plants

- Photo processing plants

- Beauty salons

Products containing contaminants:

- Chlorine-type bleaches, detergents and cleaning
solvents found in household laundry rooms

- Paint and varnish removers

- Hydrochloric acid, muriatic acid

- Chlorine-based swimming pool chemicals

- Spray cans containing chlorofluorocarbons

- Chlorinated waxes and cleaners

- Cements and glues

- Refrigerant leaks

- Calcium chloride used for thawing

- Sodium chloride used for water softening salt

- Permanent wave solutions

- Adhesives used to fasten building products and
other similar item

- Antistatic fabric softeners used in clothes dryers

12

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Pyrot Service & Maintenance

Combustion Air Supply

Safety

Codes

Provision for combustion and ventilation air must be made
in accordance with applicable local codes.

In the absence of local codes, use:

CSA B365-10, Installation Code for Solid Fuel Burning
Appliances and Equipment.
Always use latest edition codes.

WARNING

Failure to provide an adequate supply of fresh combustion
air can cause poisonous flue gases to enter living space.
Flue gases entering living space can cause carbon
monoxide poisoning which can result in severe personal
injury or loss of life.

WARNING

Never cover the boiler or store debris or other materials
near the boiler, or in any way block the flow of adequate
fresh air to the boiler. Never cover the combustion air
opening. Advise system operator/ultimate owner
accordingly.

WARNING

The boiler must not be located in areas or rooms where
chemicals are stored, or aggressive vapors (i.e. bleach,
hair spray, methyl chloride, carbon tetrachloride or
perchloroethylene) or high dust levels or humidity levels
are present. Heat exchanger corrosion might occur and
reduce the lifetime of the boiler significantly. If above
criteria are not properly observed and boiler damage
results, any warranty on the complete boiler and related
components will be null and void.

General

This equipment requires fresh air for safe operation.

The boiler location must never be under negative pressure.
Exhaust fans, attic fans, or dryer fans may cause air to be
exhausted at a rate higher than air can enter the structure
for safe combustion.

The heating contractor shall ensure all of the following
requirements are met:

- An adequate supply of combustion air must be
available to ensure proper combustion.

- Ambient air temperatures must be maintained within
safe operating limits.

- When a damper is provided in any opening intended
to admit combustion air into the room within which
the appliance is installed, the damper shall be
interlocked to prevent any boiler from starting
before the damper is fully open.

- Each duct used to convey air from the outdoors
shall have:

1. a cross-sectional area throughout its length at
least equal to the free area of the inlet and outlet
openings which it connects,

2. making a provision for outside combustion air,
the intake shall not be less than 1 ft. (0.3 m)
above the anticipated snow level for the location.

- The heating contractor must check with local
authorities (municipal building department) for
combustion air requirements particular to the area.

See “Installation and Operating Instructions” for more
details.

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13

Maintenance

Components of the Biomass Boiler

Pyrot Service & Maintenance

1 In-feed auger with isolating layer
2 Drive for moving grate
3 Moving grate
4 Drive for automatic de-ashing system (optional)
5 Igniter
6 Controlled combustion air supply system
7 Rotary blower (Viessmann-patented)

14

8 Boiler door
9 Heat exchanger

qP Rotary combustion chamber (Viessmann-patented)
qQ Safety heat exchanger for thermal safety flush valve
qW Frequency-controlled flue gas exhaust blower

qE Pneumatic cleaning system (optional)
qR Flue gas recirculation pipe

5603 880 - 01

Pyrot Service & Maintenance

Cleaning

Boiler

The heat exchanger, flue gas pipe, and chimney must be
cleaned regularly to remove accumulated creosote and ash.

Ensure that the heat exchanger, flue gas pipe, and chimney
are cleaned at the end of the heating season to minimize
corrosion during the summer months. The appliance, flue
gas pipe, and chimney must be in good condition.

With pneumatic cleaning system, after
approx. 600 operating hours; without
pneumatic cleaning system, after approx.
300 operating hours:

Open the boiler door and clean all heat
exchanger with a wire cleaning brush.
Use the ash rake to carefully draw the fly
ash lying in the rotary combustion chamber
to the front.

Maintenance

Regular cleaning and maintenance of the boiler system is
of the utmost importance to assure trouble-free operation
and to obtain the largest possible output at the best
efficiency.

The cleaning intervals listed here are for wood chip fuel
material with clinging bark with 0.8% ash content. The
cleaning intervals may vary, depending on the fuel, the
amount of fine matter and the operating conditions.

After approx. 1000 operating hours:

Disconnect the power from the flue gas
exhaust blower, loosen the butterfly nuts,
pull out the motor with impeller and clean
the assembly with a broom or wire brush.

CAUTION

DANGER OF INJURY – be absolutely sure
to turn OFF the main switch.

IMPORTANT

With pneumatic cleaning system, disconnect
the compressed air line before opening the
boiler door – danger of injury!

After approx. 300 operating hours:

Open the lid across the in-feed auger
and clear the slots in the grate.

CAUTION

RISK OF INJURY: Shut the system

off before starting any cleaning. Be

absolutely sure to wear protective

gloves, protective eyewear if required

and use the cleaning tools that come

with the system (danger of blow-ups,

burns and getting crushed)!

Check the level of the ash bin regularly and
empty the bin before it is completely full.

IMPORTANT

NEVER operate the boiler without the ash bin.

5603 880 - 01

After approx. 1000 operating hours:

Clean the recirculated flue gas line.

After approx. 300 operating hours:

Loosen and clean the light barriers
and the inspection windows on the
combustion chamber.
Remove dust and ash in the openings.

15

Maintenance

Pyrot Service & Maintenance

Cleaning (continued)

Heat exchanger displacement rods

The displacement rods improve the heat transmission in the heat exchanger and reduce the temperature of the exhaust
gas, thus improving the efficiency of the heating system. They have to be taken out to clean the heat exchanger and
put back in after cleaning.

Installing the displacement rods

Insert the displacement rods into the heat exchanger with
the thick end first. Push until they are flush with the edge
of the tube. Tolerance +/- a” (5 mm).

Removing the displacement rods

Remove the displacement rods with a pair of pliers, as
shown above. The heat exchanger should be cleaned
at the intervals prescribed so that performance and
efficiency are maintained and the displacement rods can
be easily removed.

16

CAUTION

RISK OF INJURY: Shut the system off before starting
any cleaning. Be absolutely sure to wear protective
gloves, protective eyewear if required and use the
cleaning tools that come with the system (danger of
blow-ups, burns and getting crushed)!

5603 880 - 01

Pyrot Service & Maintenance

Cleaning (continued)

Flue gas cyclone (optional)

The flue gas cyclone minimizes dust emissions and is
designed as a multi-cyclone with an axial function.
The cyclone is completely insulated and provided with a
total of three lids for cleaning. The untreated exhaust flue
gas chamber is cleaned via the cleaning lid on the side.
The clean exhaust flue gas chamber is cleaned via the top
or rear cleaning lid (unused blower connection).

The ash container, which is provided with a trolley,
connects to the cyclone by quick-action fasteners and
easily moves out for emptying. The flue gas exhaust
blower can be mounted either on top or on the side, as
desired.

After approx. 1000 operating hours:

Disconnect the power, unscrew the butterfly nuts,
pull out the motor with impeller and clean the assembly
with a broom or wire brush.

After every cleaning of the boiler heat exchanger:

Open the side lids and clean the guide blades of
the cyclone with a hand-brush.

Maintenance

CAUTION

RISK OF INJURY: Shut the system off before starting
any cleaning. Be absolutely sure to wear protective
gloves, protective eyewear if required and use the
cleaning tools that come with the system (danger of
blow-ups, burns and getting crushed)!

Check the level of the ash container
regularly and empty the bin before it is
completly full.

IMPORTANT

Never operate the boiler without an ash bin!

Pneumatic cleaning system (optional)

- Operation and maintenance of the air compressor
(optional) according to the manual that comes with
the system.

- For a field supplied air compressor, the compressor
has to be suited for continuous operation or be
secured against continuous operation (e.g. timer
for limiting running time).

- Continuous operation of the compressor indicates
leakage in the air system. Check air supply line and
valves for leakage.

Regularly drain condensation water
in the compressed air distribution bar.

5603 880 - 01

17

Maintenance

Feed Systems

Pyrot Service & Maintenance

When storage facilities for wood are required the wood
should be kept at least 5 ft. (1.5 m) from the heating
appliance.

All geared motors on the feed systems are maintenance-free.

- A change of lubricant and/or oil is recommended
every 20,000 operating hours or every three years.

- Re-lubricate flange bearings and other lubricating
points regularly with lithium soap grease.

- Check chain drives for wear and if necessary,
tighten them up and lubricate with chain oil.

- Check all bolts for tightness.

- Once a year check the extraction components
in the silo and/or bunker for damage and soiling.
Remove any foreign matter.

Funnel extraction system (AP/APS):

Lubricate the gasket between the extraction casing and
the geared motor and universal joint for the auger.

If a fuel hopper is installed, do not alter equipment in
any way. May be connected to an existing boiler or solar
system.

IMPORTANT

Never use inflammable lubricants!

CAUTION

RISK OF INJURY: Shut the system off before starting
any cleaning. Be absolutely sure to wear protective
gloves, protective eyewear if required and use the
cleaning tools that come with the system (danger
of blow-ups, burns and getting crushed)!

Note: Viessmann recommends the installation of carbon

monoxide detector(s) inside the fuel storage area.

IMPORTANT

The fuel storage area/room must be designed, operated
and maintained to national, provincial and local codes and
requirements.

WARNING

The wood chip/pellet storage room must be adequately
and permanently ventilated. Ensure the door or latches
are securely locked open during presence in the room.
No smoking, fires or open flames are permitted.

18

5603 880 - 01

Pyrot Service & Maintenance

Shutdown

Maintenance

Boiler

Heat exchanger:

- When the Pyrot is not in operation for a long
period (such as for summer breaks), be sure to
carefully clean the heat exchanger with a steel
brush as required.

- If the heating room is moist or there is any other
atmosphere that promotes corrosion (e.g. poor
ventilation, residual enamel near the heating room,
etc.), spray the heat exchanger with biodiesel
after cleaning.

- If there is a danger of frost, empty the heating
system or add antifreeze.

Extraction and conveyance systems

When the Pyrot is not in operation for a long period (such
as for summer breaks), it is recommended to empty the
fuel extraction and conveyance system of all fuel to avoid
corrosion of the equipment and decay of the wood fuel.
Refill with new fuel after checking the system and before
the boiler startup.

Control system

Even when the Pyrot is not in operation for long periods,
the power supply to the control system should not be
interrupted (do not turn off the main switch).

- The “intermittent control system” switches on the
boiler pump for five seconds every 24 hours.
This prevents the pump from jamming during long
stand stills and prevents expensive repairs.

- Prevent the formation of condensation in the oxygen
sensor.

- Extend the service life of the buffer battery.

Disposal of the boiler

- Switch off the Pyrot by pressing the F1 button.
When the burn-out has taken place and the boiler
has cooled down, turn off the main switch.

- Disconnect the power supply to the control cabinet.

CAUTION

DANGEROUS VOLTAGE!
Only a licensed electrician is allowed to disconnect and
dismantle the connection to the electrical network.

- Close the supply and return valves.

- Open the drain valve on the bottom of the boiler and
drain the water.

IMPORTANT

Only a qualified heating contractor may drain the boiler
and dismantle the connections to the heating system.

- Disconnect the supply pipe and return pipe from the
boiler.

Instructions regarding removal

Personnel removing equipment must be aware of the
risks and use suitable safety precautions.

Waste disposal

- Comply with customary laws and local regulations
on waste disposal.

- Contact a disposal company to dispose and recycle
waste in a environmental friendly way.

Replacing the buffer battery

The buffer battery is built in beneath the removable lid
on the control module (type Panasonic Lithium BR2330).
It is for buffering the time, date and settings.

Note: The battery needs replacing every five years.
DO NOT disconnect the main power or turn off the
main switch while changing the battery.

Ash disposal

- Ashes should be stored in covered metal containers
on non-combustible floors away from combustible
material.

- Comply with customary laws and local regulations
on ash disposal.

5603 880 - 01

19

Troubleshooting

Performance Problems

The boiler does not provide its original performance.

Performance

problems

Pyrot Service & Maintenance

Boiler temp.

ACTUAL <

Boiler temp.

TARGET

Yes

Exhaust

gas temp.

ACTUAL <

Exhaust gas

temp. limit

value

Yes

Residual oxygen

ACTUAL

Residual oxygen



TARGET

Yes

Fuel < W35

1 Check settings
2 Heat cannot be dissipated

No

3 Check the function of the boiler
pump and the 3-way mixing valve
F3 parametercontrol menu

1 Clean heat exchanger
F3 parametercontrol menu

No

1 Clean grate
2 Clean all four sight glasses and
pipes of the ember monitoring

No

system light barrier
3 Check the position of the light
barrier

F3 parameter control menu

1 Use proper fuel
2 Close recirculation temporarily

No

3 Open ash chamber door that
is closer to the feed auger by
2” (50 mm) temporarily

Boiler

re-establishes

its performance

No

Boiler

re-establishes

its performance

No

Boiler

re-establishes

its performance

No

Boiler

re-establishes

its performance

Yes

Yes

Yes

Yes

Fault rectified

Fault rectified

Fault rectified

Fault rectified

Yes

Open
primary
air vent

1 Check air vent moves smoothly
2 Compare opening angle on the

No

operating console
3 Check electrical connections

Yes

Check that

grate vents

move

smoothly

No

Yes

Contact Viessmann

20

1 Clean grate vents of cinder
coatings
2 Remove impurities

No

Boiler

reestablishes

its performance

No

Boiler

re-establishes

its performance

No

Yes

Yes

Fault rectified

Fault rectified

5603 880 - 01

Pyrot Service & Maintenance

Grate Drive Mechanics Jams

Grate drive mechanics are no longer running causing cinders to accumulate on the grate.

Grate drive

mechanics jammed

Troubleshooting

Check electrical

triggering system

Check shear-off pin

Clean the connecting

rod and bronze bearing

Check grate

 Set the system to “Cleaning”, this

causes the grate drive motor to run
continuously.

 Check that the shear-off pin on the

connecting rod is OK.

 Check that a spare shear-off pin is

present.

 Cleaning of the connecting rod and

of the bronze bearing by means of
grease removers.

 Check grate for foreign material.

Check grate factory settings

5603 880 - 01

 Are all grate components properly inserted?
 Lateral play - sliding grate for the concrete;

3

/16”1/32” (51 mm) (applies up to KRT 300)

5

/16”1/16” (82 mm) (applies up to KRT 400/540)

 Crank axle distance;

KRT 100/150 1e”(35 mm)
KRT 220/300 2
KRT 400/540 3

 Setting, stop position, sliding grate “back” crank drive right in

the back - movable grate components, front approx.

5

/32” (55 mm)

5

/32” (80 mm)

1

/16”- 5/32”

(2-4 mm) play (adjustment via threaded rod)

 Setting, movable grate components, “front” crank drive right

in the front - movable grate components, front project approx.

5

/16” (8 mm) beyond the fixed parts and have approx. 1/16”- 5/32”

(2-4) mm play (adjustment via adjusting screw at the bottom
on the grate).

21

Troubleshooting

Pyrot Service & Maintenance

Checking for Increased Wear of Fireclay

Increased fireclay wear can be observed in the substructure or in the curved bricking.
Fireclay must only be replaced when:

the curved bricking is broken downwards (not already in the event of formation of cracks or spalling)
fireproof panel located on the back of the fireclay can be seen in the substructure

Checking for increased

wear of fireclay

 Cleaning in the area of the arch in the chimney

Check the recirculation system

and in the area of the opening of the shut-off
valve

 Recirculation must be hot at partial load

Check damper

Check fireclay for discoloration

 Damper must be installed
 Damper must not be fully open (chimney draft

may be too strong)

 If discoloration is visible in the fireclay
 If there is discoloration, often halogen

substances have been burned

22

5603 880 - 01

Pyrot Service & Maintenance

Troubleshooting

Checking the Inside of the Boiler Door

Checking the inside of the boiler door can indicate whether the fibre glass seal is properly applied. If the seal is not
properly applied, higher levels of CO gas can form. Checking the inside of the door can also indicate whether the
guide tube is indicating increased wear. This is a danger especially at higher temperatures.

Checking the inside

of the boiler door

 Check guide tube for deformation

(possible cause of deformation:

Check guide tube

Overheating If there is increased wear
of the fireclay, perform check (see section
checking for increased wear of Fireclay)

 Check guide tube for wear

Check boiler door seal

Check fireclay boiler door

 Seal must fit properly and be caulked
 Procedure if a seal is leaking

Replace ceramic packing of the seal,
check by means of impression test
that the whole surface of the seal lies
on the ceramic packing, increase seal
contact pressure in KRT-400/540 with
the screws outside on the door

 Check fireclay erosion
 The formation of cracks and spalling

outside the glass fibre packing only
constitutes an optical imperfection

 Complaints must be made in the event

of fireclay erosion inside the glass fibre
packing from ~ 3d”(80 mm)

5603 880 - 01

23

Troubleshooting

Pyrot Service & Maintenance

Checking Oxygen Control System

A check of the oxygen control is carried out in case of incomplete combustion, dark smoke escaping the chimney or
performance problems.

Checking the oxygen

control system

Visual check of wiring

Clean the oxygen sensor

xygen display

o

with fresh air

between

20% - 21%

No

 Check that all electrical lines are

permanently connected

 Clean the outside of the oxygen

sensor using a wire brush

 Hold the oxygen sensor downwards

and gently tap out with the bristles of
the wire brush until no more dirt falls
out of the probe

 Balance the oxygen sensor (see

section on balancing the oxygen
sensor)

Yes

Install the oxygen sensor

so it is leak tight

Check the boiler

24

 Set the heating system to cleaning
 Check the leak tightness of the

installation with the flue

 Close the doors of the exhaust gas

collector and boiler door airtight
(check with the flue)

 Pneumatic cleaning system is

operational and leak tight

5603 880 - 01

Pyrot Service & Maintenance

Troubleshooting

Balancing the Oxygen Sensor

The oxygen sensor is subject to ageing which can be compensated by a oxygen sensor compensation.
The oxygen sensor compensation is necessary if the residual oxygen to fresh air is <20%.

CAUTION

The oxygen sensor is constantly heated and is very hot.

Balancing the oxygen sensor

 Clean the oxygen sensor using a wire brush

Remove and clean
the oxygen sensor

 Hold the oxygen sensor downwards and gently

tap out with a wire brush until no more dirt falls
out of the sensor

 Let the oxygen sensor hang freely in the air

without contact to metal

Measure the oxygen

sensor signal

Boiler status “off”

Balance the oxygen sensor

 The oxygen sensor must be supplied with a

heating voltage in the range between 13.0 and

13.8V (measured at the white/white wires)

 The heating voltage can be adjusted on the main

board

 The signal voltage must be in the range between

-6 and -11 mV (measured at the grey-/black+wires)

 The boiler status must be “off” and the exhaust

gas temperature must be <122°F (50°C)

 The oxygen sensor must be supplied with current

for min. 5 minutes

 Carry out the oxygen sensor balancing in the

operating console
Press OK+F3 (simultaneously)parametercontrol
menu option 68

 Wait for the confirmation”Active”

Install the oxygen sensor

5603 880 - 01

 Install the oxygen sensor so it is leak tight
 Check again with the flue

25

Troubleshooting

Heating System Faults

Pyrot Service & Maintenance

Fault
No.

01 Excess temperature

03-17 Interruption or

09 Oxygen sensor

18 Permanent code

19 Repeat heating up

20 Water level in

25 Light barrier, ember

26 Light barrier,

96 Feed auger pipe

81-93 BUS error, no

53-54 Extraction system

Text displayed Indicator Possible cause Check / remedy

(red light at F1, F2,
F3)

short-circuit, sensor

(red light at F3)

(red light at F3)

(red light at F3)

extinguishing
Water container

(red light at F3)

monitoring system

(red light at F3)

feed auger

(red light at F3)

too hot

connection to the

(red light at F3)

… silo door open
(red light at F4)

Fixed high limit
N21

- Sensor . . . - Damaged sensor connection line

- Oxygen sensor
in the flue
gas pipe

- Operating hours
lapsed before the
permanent code
has been entered

- Exhaust gas
temperature
sensor

- Oxygen sensor

- Level float switch
in extinguishing
water container

- Light barrier for
ember monitoring
system

- Light barrier in
the metering
container for the
feed auger

- Temperature
sensor on the
feed auger

- Data transmission
line for the bus
connection

- Limit switch for
silo door

- Incorrect setting in the
control module

- Defective component (pump
or valve)

- Sudden drop in output to zero.
The feed auger then has to be
emptied. The heat produced
by this can result in excess
temperature. Activate the
function “Dissipate excess
heat”

- Indicator defective

- Indicator very soiled

- Indicator defective

- Error in the electronics

- Permanent code has not been
entered

- Fuel too moist

- Oxygen sensor imprecise

- Igniter defective

- The combustion chamber
filling time is too short

- Not enough water in the
extinguishing water container

- Sight glass soiled;
deposits of ash in the openings

- Defective indicator

- Light barrier soiled

- Clogging in the metering
container

- Power failure

- Consequent malfunction
caused by excess temperature

- Light barriers for ember
monitoring system soiled

- Bus connection interrupted - Check plug connections

- Silo door open - Check and close silo door

- Why could the heat not be
dissipated?

- Check the boiler pump and
mixing valve

- Activate the function
“Dissipate excess heat”

- Unscrew the protective cap on
the fixed high limit and press
the reset button (not
possible until the boiler
temperature is less than 158°F
(70°C) and press OK

Call a qualified electrician

- Readjust oxygen sensor

- Acknowledge with OK

- Call Viessmann

- Use suitable, dry fuel

- Readjust oxygen sensor.

- Replace ignition device

- Readjust combustion chamber

- Acknowledge with OK

- Fill extinguishing water container

- Acknowledge with OK

- Remove and clean sight glasses
on both sides

- Remove dust and ash deposit
from the openings

- Refer to the section,
“Cleaning”

- Acknowledge with OK

- Clean light barrier

- Remove clogging

- Acknowledge with OK

- Call a qualified electrician

- Check light barriers for embers

- Acknowledge with OK

- Replace data transmission line

- Call Viessmann

- Acknowledge with OK

26

5603 880 - 01

Pyrot Service & Maintenance

Loader System Faults

Troubleshooting

Fault
No.

01 Material shortage

11-24 Soft starter …

30 Feed auger

31-45 Conveyor device …

51-52 Extraction system …

Text displayed Indicator Possible cause Check / remedy

(red light at F4)

(red light at F4)

(red light at F4)

(red light at F4)

(red light at F4)

- Light barrier in the
metering container

- Light barriers for the
ember monitoring
system

- Soft starter

- Red light at the soft
starter

- Reversed control of
in-feed auger

- Maintenance cover
limit switch

- Maintenance cover
limit switch

- Silo is empty

- Conveyance system is
clogged/jammed

- Phase sequence mixed up

- Motor overloaded

- Other causes, depending
on the malfunction displayed

- Material clogging in the
in-feed auger

- One of the maintenance
covers is open or not
closed properly

- One of the maintenance
covers is open or not
closed properly

- Fill silo

- Turn off main switch and
remove material clogging

- Acknowledge with OK

- Correct the phase sequence
(clockwise rotating
magnetic field)

- Remove clogging

- Refer to documentation for
soft starter

- Acknowledge with OK

- Remove material clogging

- Check and close all the
maintenance covers

- Acknowledge with OK

- Check and close all the
maintenance covers

- Acknowledge with OK

53-54 Extraction system

… Hydraulic drive,
temperature/level

(red light at F4)

53-54 Extraction system …

silo door open

(red light at F4)

01-27 Interruption or short-

circuit, sensor …

(red light at F4)

- Level float switch
in the oil container
for the walking floor
extraction system

- Thermostat in the
oil container

- Limit switch for silo
door

- Sensor . . . - Damaged sensor

- Oil level too low, (possible
loss of oil)

- Oil has been overheated by
too high pressure

- Silo door open - Check and close silo door

connection line

- Indicator defective

- Refill oil. Check oil line for
leakage

- Check and adjust operating
pressure

- Acknowledge with OK

- Acknowledge with OK

- Call a qualified electrician

5603 880 - 01

27

Pyrot Service & Maintenance

Printed on environmentally friendly

(recycled and recyclable) paper.

Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island · 02886 · USA
1-800-288-0667 · Fax [phone]
www.viessmann-us.com · [e-mail]

Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario · N2V 2G5 · Canada
1-800-387-7373 · Fax [phone]
www.viessmann.ca · [e-mail]

Technical information subject to change without notice.

5603 880 - 01