Viessmann VITOMAX 200-HS Operating And Service Instructions
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Viessmann VITOMAX 200-HS Operating And Service Instructions

Oil/gas high pressure steam boiler with or without economiser rated steam output 0.5 to 4.0 t/h
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VIESMANN
Operating and service
instructions
for contractors
Vitomax 200-HS
Type M73A
Oil/gas high pressure steam boiler
With or without economiser
Rated steam output 0.5 to 4.0 t/h
VITOMAX 200-HS
Please keep safe.
5607 288 GB
9/2011

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  • Page 1 VIESMANN Operating and service instructions for contractors Vitomax 200-HS Type M73A Oil/gas high pressure steam boiler With or without economiser Rated steam output 0.5 to 4.0 t/h VITOMAX 200-HS Please keep safe. 5607 288 GB 9/2011...

  • Page 2: Safety Instructions

    ■ Close the quick-acting fuel ■ The system must be commissioned by valve and shut-off valve. Viessmann Industrieservice, the sys- ■ Open windows and doors. tem installer or a qualified person ■ Remove all people from the authorised by the installer.
  • Page 3 ■ Ventilate boiler room. tem. Replace faulty components only Working on the system with original Viessmann spare parts. ■ Close the fuel shut-off valve and secure against unintentional opening. Auxiliary components, spare and ■ Isolate the system from the power sup-...
  • Page 4 Safety instructions Safety instructions (cont.) Draining condensate from the flue Subject to the regulations in the country gas side concerned, this condensate may need to be neutralised. In such cases, consult Please note the local water authority or the relevant When the boiler system starts or body responsible for issuing permits.
  • Page 5 Safety instructions Technical safety information (cont.) Obvious signs at weld seams, leaking damaged areas, severe corrosion, unusual characteristics of operating instruments and system components as well as unusual noise inside the boiler must be notified immediately. Faults and defects on the system that cannot be remedied by experts locally must be noti- fied to the manufacturer.

  • Page 6: Table Of Contents

    Index Index Operating instructions Operating information Storage of Vitomax boilers prior to installation as part of the system....Operating tips....................... Functions......................Shutting down the system..................17 Preservation......................17 Maintenance instructions..................21 Service instructions Water quality Water quality for steam boiler systems..............22 Commissioning Preamble......................

  • Page 7: Operating Information

    TRD 604. authorised expert has tested the sys- The system must be commissioned by tem. the Viessmann Industrieservice, the sys- According to the Steam Boiler Order tem installer or a qualified person author- [Germany], steam boilers category IV...
  • Page 8 Operating information Operating tips (cont.) Record all actual values in a test report. In systems comprising several boilers, of These must be confirmed by the instal- which one is constantly used as standby ler, the relevant expert and the system boiler, only change the operation over operator.

  • Page 9: Functions

    Operating information Functions Installation drawing wQ wW wT wZ rErR 1 Illustrative example. Order-specific deviations from the standard delivery are possi-...
  • Page 10 Operating information Functions (cont.) ble. Note Illustration of the fitting assembly refers to modulating operation. Provide two further pressure regulators for stepped operation; the pressure transducer for the burner control will then not be required. 1 Platform wQ Air vent shut-off valve 2 Control panel wW Steam shut-off valve See separate documentation...
  • Page 11 Operating information Functions (cont.) Level electrodes qP to qW Permanently modulating level monitoring qP Level electrode for continual and load-dependent boiler filling Function Method of opera- Operating information tion Continual water level con- Water level below or The controller issues a pulse to the trol comprising exceeds the selec- feedwater control valve...
  • Page 12 Operating information Functions (cont.) Level monitoring water level "too high" (HW electrode qQ) Level electrode to safeguard against maximum water levels Function Operating condi- Operating informa- tion tion Self-monitoring overfill protection Standard water Electrode is not comprising level immersed in the con- ■...
  • Page 13 Operating information Functions (cont.) Level monitoring water level "too low" (NW electrode qW) Level electrode to safeguard against minimum water levels Function Operating condi- Operating informa- tion tion Self-monitoring low water indicator Standard water Electrode is immersed comprising level into the conducting ■...
  • Page 14 Operating information Functions (cont.) Air vent shut-off valve wQ Function Operation Operating information Venting the boiler During heat-up, Air / steam must be able to be routed away during filling or open the valve and safely after a new sys- close it again, as tem start from soon as visible...
  • Page 15 Operating information Functions (cont.) T.D.S. unit wU and wI Function ■ Continual checking and regulation of the salt content through temperature- compensated conductivity electrode ■ Desalination via the TDS valve ■ Maintenance of specified limits by opening and closing the valve Method of operation Operating information Conductivity drops...
  • Page 16 Operating information Functions (cont.) Pressure monitoring facility rQ to rR Component Function Operating information The pressure moni- toring unit is directly connected to the boiler via the fitting assembly and com- prises ■ Pressure gauge rQ Operating pressure Operating checks at regular intervals indicator or in accordance with country-specific regulations...

  • Page 17: Shutting Down The System

    Operating information Functions (cont.) Sampling cooler rZ Function Operating information Removal of water samples to carry out Values to be checked in accordance with comparative tests country-specific regulations and to be recorded in the boiler log ■ pH value ■ Residual hardness ■...

  • Page 18: Wet Preservation

    Operating information Preservation (cont.) Wet preservation 1. Fill the boiler incl. economiser (if Never use this procedure where there installed) up to the highest possible is a risk of frost. level with treated feedwater. To pre- Apart from the chemical wet preserva- vent oxygen corrosion, add an oxygen tion, physical-technical methods may binder to the boiler water (e.g.
  • Page 19 Operating information Preservation (cont.) Sodium sulphite excess Idle time Sodium sulphite con- Additional sodium sul- tent in the preserva- phite tion solution mg Without Crystal- water g/m lised g/m Fill water for steam boilers: ■ Water of low salt 1 week 20 - 50 20 - 50 40 - 100...

  • Page 20: Dry Preservation

    Operating information Preservation (cont.) Dry preservation Note Dry out components, such as econo- This method is used when longer idle misers, separately. periods are expected and to ensure pro- Position desiccants (e.g. silica gel, blue tection against frost. This method means gel) in shallow bowls inside the open and that a quick return of the system into use drying boiler or hang them inside the...

  • Page 21: Maintenance Instructions

    VGB (no. R116H, 1981) [or local regula- tions]. Maintenance instructions The TRD regulation specifies the main- tenance of a steam boiler system, which can be carried out by the Viessmann Industrieservice or by an authorised con- tractor. You can contact Viessmann Industrie- service on Tel.: +49 (0)30/6602 389...

  • Page 22: Water Quality

    Water quality Water quality for steam boiler systems Steam boilers In its natural state, most untreated water The requirements are monitored by will be unsuitable as boiler feedwater. measurements made by suitable, pref- The type of boiler feedwater treatment erably uncomplicated devices (either should be matched to the raw water every 24 h or 72 h or in line with national quality.
  • Page 23 Water quality Water quality for steam boiler systems (cont.) Permiss. operating > 0.5 < 20 > 20 pressure Total alkaline earths mmol/litre < 0.01 < 0.01 + Mg Oxygen (O mg/l 0.05 < 0.02 Bound carbon dioxide mg/l < 25 <...
  • Page 24 Water quality Water quality for steam boiler systems (cont.) Feedwater conductivity > Feedwater conduc- tivity ≤ 30 µS/cm 30 µS/cm Permiss. oper- > 0.5 to 20 > 20 > 0.5 ating pressure Phosphate mg/l 10 to 20 10 to 20 6 to 15 Silicic acid mg/l...
  • Page 25 Water quality Water quality for steam boiler systems (cont.) Maximum permissible direct boiler water conductivity, subject to pressure Feedwater conductivity >30 μS/cm 10000 8000 4000 2000 1000 Operating pressure in bar...
  • Page 26 Water quality Water quality for steam boiler systems (cont.) Maximum permissible boiler water silicic acid content (SiO ), subject to pres- sure 15 B 10 B 0.5B Operating pressure in bar A This level of alkalinity is no longer permissible >20 bar - value in mmol/l S 8.2 Conditioning...
  • Page 27 Water quality Water quality for steam boiler systems (cont.) General information regarding conditioning ■ Conductivity If organic conditioning agents are used, – Saline the amounts and processes to be used This means feedwater with electrical as well as the required analyses must be conductivity of >30 µS/cm (e.g.
  • Page 28 Water quality Water quality for steam boiler systems (cont.) Deviation during conditioning Actual values deviating during constant Carry out immediate changes to rein- operation from those specified may be state the correct operation. For example, the result of the following: feeding in returned condensate must not ■...
  • Page 29 ISO 10523 value and both conductivities. Phosphate ISO 6878–1 Viessmann offers components for water Potassium ISO 9964–2 analysis to aid continual monitoring of Silicic acid the O and pH values as well as water Sodium ISO 9964–1...
  • Page 30 Water quality Water quality for steam boiler systems (cont.) Measure the acid conductivity in the form of the hydrogen ion concentration con- tinuously in the same manner as the con- ductivity in hydrogen form, after the sam- ple has gone through a severely acidic ion exchanger with a volume of 1.5 l.

  • Page 31: Commissioning

    Commissioning Preamble This manual contains general informa- tion regarding the installation, commis- sioning, operation, maintenance and inspection. It must be supplemented and specifically adapted in accordance with country-specific regulations. In addition, any instructions for the equipment and auxiliary systems that are part of the boiler system must be incorporated into the manual supplied with the system.

  • Page 32: Access To Boiler Rooms

    Commissioning Installation (cont.) Clearances for operation and maintenance Areas that must be accessed for control The clearance between the boiler top and maintenance of the steam boiler and the ceiling above must be at least system must offer a head clearance of at 0.75 m, when access to that area is least 2 m and a clear width of at least required for operation and mainte-...

  • Page 33: Commissioning

    Commissioning First commissioning Generally, commissioning is carried out by Viessmann Industrieservice, the sys- tem installer or a contractor authorised by them. Commissioning preparations Prior to commissioning the boiler, the fol-...

  • Page 34: Starting The Boiler

    Commissioning Commissioning (cont.) ■ Checking the pipework depending on ■ Testing the lighting system. version (e.g. retainers, expansion ■ Checking the availability of fire fighting joints, drainage systems, emptying, and "First Aid" equipment. venting). ■ Opening the front cleaning apertures ■...
  • Page 35 Commissioning Commissioning (cont.) ■ Boilout ■ When installing an economiser, are See page 37 the air vent valve and drain closed? ■ Plugs/closures on the water side ■ Are the water level glasses open? See page 37 Flush on the DHW side if required. Commissioning the control panel Adjusting the water level control ■...

  • Page 36: Commissioning The Burner

    Commissioning Commissioning (cont.) ■ Let the water level return to the zero No unauthorised personnel should be in point by opening the blow-down valve the boiler house when the burner is and readjust at the controller being commissioned. ■ Bring the boiler to the required water Once the combustion is steady, raise the level and adjust at the controller operating pressure under partial burner...
  • Page 37 Commissioning Commissioning (cont.) Once the safety pressure limiter has The safety valve must open when the set responded and a fault shutdown of the pressure has been reached; this must be boiler has been carried out, the safety equal to or lower than the maximum per- pressure limiter should be reset after a missible operating pressure of the boiler.
  • Page 38 Commissioning Commissioning (cont.) Verification Create a first commissioning report where the established and set values are recorded. This report must be signed by the customer. Instructions Instruct the operating personnel after the first commissioning. Create a report regarding these instructions. Returning the boiler into use after idle periods Generally, it would be the local operators ■...
  • Page 39 Commissioning Commissioning (cont.) The length of the shutdown period also determines the preservation measures described in chapter "Preservation". A short-term shutdown is not recommen- ded, as every start-up process subjects the boiler to additional stresses. For a period of up to 24 hours or over a week- end, the boiler should continue in oper- ation.

  • Page 40: Utilisation And Operation

    72 hours without supervision means every three days. Every 6 months/12 months: These checks should be carried out by a spe- cialist contractor, e.g. the Viessmann Industrie- service or the manufacturers of the boiler sys- tem, combustion equipment or water treat- ment.

  • Page 41: What To Do In Case Of Operating Faults

    Utilisation and operation What to do in case of operating faults Note ■ Irregularities in the combustion opera- See technical safety information on tion or a deflagration have/has occur- page 4. ■ Medium is leaking from the pressure Generally, the operating instructions part of the boiler should be observed regarding action in If dangerous conditions for boilers exist,...

  • Page 42: Repairs And Inspection

    Repairs and inspection Repairs General requirements Work in areas at risk may only com- mence if the system or parts of the sys- Repair work may only commence after tem have previously been reliably dep- the person responsible for such repairs ressurised and are also not under nega- has determined the required safety tive pressure, that this state has been...

  • Page 43: Inspection

    Repairs and inspection Inspection Entering the steam boiler During the entry into the steam boiler and flues, electrical equipment may only Prior to entering the steam boiler, pipe be used if, including its cables and leads, connections (steam, feed and drain it complies with the relevant safety reg- facilities) to the operational boiler must ulations and has been provided by the...

  • Page 44: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Commissioning the system........... 45 • • 2. Shutting down the system..........46 •...

  • Page 45: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Commissioning the system Details provided by the burner 09. Open the shut-off valves in the oil or manufacturer and regarding gas line. accessories 10. Switch ON the mains isolator, the 01. Check that the turbulators (if instal- switch for the equipment required led) are fully pushed into the hot gas for the boiler system and the burner...

  • Page 46: Shutting Down The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 15. Observe the pressure and temper- 18. Check the boiler doors and cleaning ature test equipment. covers for leaks after approx. 50 hours and retighten all screws (tor- 16. If required, drain and vent the con- que approx.

  • Page 47: Removing The Burner (If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Removing the burner (if required) 1. Remove the fuel supply line. 2. Undo screws B and remove burner with burner plate A. Please note Ensure the burner and burner plate are not twisted on removal.

  • Page 48: Opening The Cleaning Cover

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Opening the cleaning cover 1. Flue gas collector ■ Remove nuts A and cleaning cover B. 2. Flame tube entry ■ Remove screws C and pivot open cleaning door D. 3.

  • Page 49: Cleaning Heating Surface And Flue Gas Collector

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning heating surface and flue gas collector 1. Clean flues A, flame tube B and reversing chamber with pneumatic cleaner and remove combustion res- idues. 2. Remove combustion residues from the flue pipe and the flue outlet.

  • Page 50: Cleaning The Sight Glass In The Cleaning Aperture

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the sight glass in the cleaning aperture Sight glass with gaskets A should be checked for tightness and cleaned.

  • Page 51: Checking Thermal Insulation Components And Gaskets

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking thermal insulation components and gaskets...
  • Page 52 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Check all gaskets/seals A and insulat- ing parts for damage and a firm seat. Note Only undamaged and properly fixed materials protect against the egress of gas and overheating, and consequently against material damage and injury.

  • Page 53: Inserting Turbulators (If Appropriate) And Closing The Boiler Doors

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Inserting turbulators (if appropriate) and closing the boiler doors 1. Push turbulators A using turbulator extractor B as far as they will go. 2. Close boiler door C, tighten screws D evenly and diagonally (torque approx.

  • Page 54: Securing The Cleaning Cover

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Securing the cleaning cover Fitting in reverse order, as described on page 48. Mounting the burner 1. Secure burner plate A with screws B to the burner flange. 2. Thermally insulate the space between the flame head (burner) and the burner opening (boiler).

  • Page 55: Checking The Inspection Ports For Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the inspection ports for leaks Note Gasket manufacturer's installa- Replace the gaskets every time a con- tion instructions. nection has been opened. Only use gaskets approved in accord- ance with TRD 401, appendix 1 or VdTÜV [or local regulations].

  • Page 56: Spare Parts

    Spare parts Wearing parts, gaskets Note When ordering spare parts, please quote the serial number and the boiler type (see type plate). Quote required number of spare parts. Obtain standard parts from your local trade supplier.
  • Page 57 Spare parts Wearing parts, gaskets (cont.)
  • Page 58 Spare parts Wearing parts, gaskets (cont.)

  • Page 59: Appendix

    Appendix Operating, maintenance and inspection tasks...
  • Page 60 Appendix Operating, maintenance and inspection tasks (cont.)

  • Page 61: Keyword Index

    Keyword index Keyword index Installation requirements....31 Access to boiler rooms.......32 Instructions.........38 Adjusting the water level control..35 Air vent shut-off valve......14 Level monitoring.........11 Lighting..........33 Blow-down.........14 Boiler log..........40 Boilout..........37 Platforms and handrails.....33 Plugs/closures on the water side..37 Preserving the hot gas side....20 Checking the water level limiting equip- Pressure monitoring facility....16 ment...........36...
  • Page 64 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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