Viessmann Vitomax HS M73 Operating And Service Instructions
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Viessmann Vitomax HS M73 Operating And Service Instructions

High pressure steam boiler
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Viesmann
Operating and service instructions
for contractors
Vitomax HS
Type M73
Type M75
Type M93
Type M95
High pressure steam boiler
VITOMAX HS
Please keep safe.
5837984 GB
1/2019

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  • Page 1 Viesmann Operating and service instructions for contractors Vitomax HS Type M73 Type M75 Type M93 Type M95 High pressure steam boiler VITOMAX HS Please keep safe. 5837984 GB 1/2019...

  • Page 2: Electrostatic Discharge

    Safeguard the system against reconnection. tion can compromise the safe operation of the ■ system. Hot surfaces Replace faulty components only with genuine Viessmann spare parts. Danger Hot surfaces can lead to burns. Never touch hot surfaces, e.g. ■ Steam pipes ■...

  • Page 3: Safety Instructions

    This applies in particular to the disposal of thermal lidate our warranty. insulation materials and gaskets/seals on the gas side. For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system General Draining hot water...
  • Page 4 Safety instructions Safety instructions (cont.) Faults and defects that cannot be remedied locally must be reported to the manufacturer. Protect all boiler parts and control equipment from rain, water leaks and expelled steam.
  • Page 5 Index Index 1. Information Symbols ....................Note ....................... Designation of boiler types ..............Intended use ..................Systems with operating temperatures 110 °C ........> 2. Functions Installation overview ................Description of selected components in a steam boiler system ....10 Level electrodes ..............
  • Page 6 Index Index (cont.) 7. Repairs and inspection Maintenance ..................31 General requirements ................. 31 ■ Working on the boiler system ............. 31 ■ Inspection ....................31 Safe inspection of the steam boiler ............ 31 ■ Inspections ..................32 ■ 8. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......

  • Page 7: Designation Of Boiler Types

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...
  • Page 8 Information Intended use The appliance is intended solely for installation and All other use is deemed inappropriate. Any resulting operation in sealed unvented heating systems, with losses are excluded from the manufacturer's liability. due attention paid to the associated installation, serv- ice and operating instructions.

  • Page 9: Installation Overview

    Functions Installation overview wUwI wTwZ Fig. 1 Example installation diagram. Standard deliv- ery may vary subject to order. Note Steam shut-off valve CE-approved boiler with accessories fitted on site. Feedwater shut-off valve Standard delivery may vary subject to order. Feedwater check valve Blow-down shut-off valve Boiler control platform with conductor (optional) Blow-down valve...
  • Page 10 Functions Description of selected components in a steam boiler system Detailed information Manufacturer's documents for the individual components Level electrodes Permanently modulating water level control Level electrode for continual and load-dependent steam boiler filling Function Operation Operating information Continual water level control comprising: Water level differs from set The controller issues pulse to Level electrode...
  • Page 11 Functions Description of selected components in a steam… (cont.) Lowest water level (NW electrode/low water level LWL Level electrode to safeguard against water shortage Function Operating condition Operating information Self-monitoring low Standard Burner operation enabled. water indicator com- water level Safety chain closed.
  • Page 12 Functions Description of selected components in a steam… (cont.) Blow-down Function: Periodic removal of deposits from the boiler Operation Operating information Regular automatic blow-down via au- Program switch opens the blow-down valve via the control valve. Briefly tomated programs drain off the boiler water. The resulting suction removes the sludge from the steam boiler.
  • Page 13 Functions Description of selected components in a steam… (cont.) Operation Operating information Regular operating checks. Observe country-specific Close the valve on the water and steam side regulations. Open flushing valve, drain and check the valves for tight- ness Open the valve on the water side; check for discharge noise Close valve on the water side Open the valve on the steam side;...
  • Page 14 Functions Description of selected components in a steam… (cont.) Sample cooler Function Operating information Removal of water sam- Measure and document the following values in the operator's log: ples to carry out compara- pH value ■ tive tests Residual hardness ■...
  • Page 15 Shutdown and preservation Shutdown Shutdown means shutting down the system via the cir- If pressure can be reduced via an additional pressure cuit breaker at the control panel. The duration of the regulator or via the programmable logic controller shutdown determines the preservation measures (PLC), then the boiler pressure can be reduced by up described in this chapter.
  • Page 16 Shutdown and preservation Shutdown (cont.) Interruption in operation 3 days > Treatment for preservation of the water side 2. Note To prevent oxygen corrosion, mix oxygen binder, Dry preservation e.g. sodium sulphite, into the boiler water in accordance with the manufacturer's instructions. Note Restarting the system quickly is not possible.
  • Page 17 Shutdown and preservation Shutdown (cont.) Sodium sulphite excess Type of fill water for steam Idle time Sodium sulphite concentra- Additional sodium sulphite boilers tion Na in preserving Desiccated Crystallised solution mg/l Low salt content, fully desali- 1 week 20 - 50 20 - 50 40 - 100 nated or condensate...

  • Page 18: Information On Maintenance

    ■ Observe the specified maintenance intervals ■ Only use authorised companies: – Viessmann Industrial Service (see contact details) Other authorised contractors – Preventing excessive flue gas temperatures Excessively high flue gas temperatures make the Recommendation...

  • Page 19: Standard Values For Water Quality

    ■ Amounts of top-up water Recommendation Chemical consumption ■ Contact Viessmann for a quotation for a water treat- Required maintenance ■ ment system. The operator's log can be used to simulate the operat- If required, there must be an option to add oxygen ing conditions at any time.
  • Page 20 Water quality Saline boiler feedwater requirements Permissible operating pressure ≤ ≤ > General requirements Colourless, clear, free of undissolved substances pH value at 25 °C > Conductivity at 25 °C S/cm Only standard values applicable to boiler water µ mmol/ l <...

  • Page 21: Water Quality

    Water quality Saline boiler feedwater requirements (cont.) Permissible direct conductivity of the boiler water, subject to pressure; feedwater conductivity S/cm > μ 7000 6000 4000 2000 Operating pressure in bar Fig. 2 Direct conductivity Conversion: = 5.6 °dH 1 mol/m 1 °dH = 0.179 mol/m 1 mval/kg = 2.8 °dH...
  • Page 22 Water quality Saline boiler feedwater requirements (cont.) Salt-free Preventing stress corrosion cracking ■ Feedwater with an electrical conductivity of If the recommended pH range is not achieved with < 0.2 S/cm and silicic acid concentration sodium phosphate alone, sodium hydroxide may be µ...

  • Page 23: Sample Analysis

    The samples must be analysed to ensure that the Recommendation boiler water properties match the values specified in Please contact Viessmann for a quotation for water Tab. 15 and 16. analysis components to aid continual monitoring of If the boiler water properties are analysed according to...
  • Page 24 Water quality Saline boiler feedwater requirements (cont.) Recommendation Oxygen ISO 5814 Use an ion exchanger with a colour display and a pH value ISO 10523 transparent cylinder. This allows you to determine the Phosphate ISO 6878 – level of depletion. Potassium ISO 9964 –...

  • Page 25: Preparations For Commissioning

    Commissioning Recommendation for commissioning Approved for commissioning: The local flue gas inspector must be notified of the ■ Viessmann Industrial Service GmbH (for contact commissioning within 4 weeks. details see 30) or ■ System installer Recommended operating conditions ■ An approved contractor or institution nominated by ■...
  • Page 26 Commissioning Commissioning sequence (cont.) Commissioning the feedwater pumps Filling the pumps with medium ■ Starting the pumps and checking the rotational direc- ■ tion ■ Adjust the operating pressure of the pumps during the first filling of the boiler. Supply pressure must be lower than the max.
  • Page 27 Commissioning Commissioning sequence (cont.) Commissioning the burner Requirements Any required gas warning equipment must function Fuel supply is enabled. correctly. No unauthorised personnel should be in the ■ ■ For gas combustion: boiler house when the burner is being commissioned. –...
  • Page 28 Commissioning Commissioning sequence (cont.) TDS controller adjustment Set according to the manufacturer's specifications. Agree the control value with the user. Test the limit The max. possible conductivity of the boiler water is value switch function regarding the max. conductivity stated in the water standards, e.g. EN 12953-10 or the by reducing the set value.

  • Page 29: Testing Intervals

    "Day" means "every 3 days". ■ Every 6 months/12 months If possible, these checks should be performed by a contractor service department, e.g. Viessmann Industrieservice or the manufacturer of the boiler system or burner, or by the water treatment com- pany.
  • Page 30 Monitoring What to do in the event of operating faults (cont.) Contact details for Viessmann Industrial Service GmbH Telephone: +49 180 3843776 Email: industrialservice@viessmann.com...

  • Page 31: Maintenance

    Repairs and inspection Maintenance General requirements Repair work may only commence after the person Additives, such as sealing compounds or separating responsible for such repairs has carried out the follow- agents must generally not be used. Exceptions require ing steps. the agreement of the gasket manufacturer.
  • Page 32 Repairs and inspection Inspection (cont.) When inspecting the steam boiler and flues, only elec- The same regulations for hand-held electrical devices. trical equipment provided for that purpose by the oper- If lamps or hand-held devices are being fed from an ator or their representative may be used.
  • Page 33 Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • • 1. Commissioning the system....................34 • • 2. Shutting down the system....................35 • 3. Removing the burner (if required)..................35 •...
  • Page 34 Commissioning, inspection, maintenance Commissioning the system Operating instructions for burner and accesso- 15. Vent the boiler at the air vent valve during heat-up ries until steam is expelled. Then close the valve. 01. Check that the fuel being used is permissible for Note the current system configuration.

  • Page 35: Shutting Down The System

    Commissioning, inspection, maintenance Shutting down the system Danger 2. Close the shut-off valves in the oil lines (at the tank Opening pressurised boiler connections and clo- and filter) or the gas shut-off valve. sures on the water and/or steam side may result in serious injury.
  • Page 36 Commissioning, inspection, maintenance Removing the inspection port closures 1. Flue gas collector 1. Undo screws from insulating fascia remove together with thermal insulation mat 2. Undo screws and remove cleaning cover 2. Flame tube entry Remove screws and pivot cleaning door open.
  • Page 37 Commissioning, inspection, maintenance Cleaning the heating surface and flue gas collector 1. Clean flues , flame tube and the reversing chamber and remove combustion residues. 2. Remove combustion residues from the flue pipe and the flue outlet. Fig. 9 Cleaning Economiser heating surfaces 1.
  • Page 38 Commissioning, inspection, maintenance Checking the thermal insulation components and gaskets Fig. 12 Check gaskets and thermal insulation sections replace if necessary. Inserting turbulators (if installed) and closing boiler door(s) 1. Fully insert turbulators into the 3rd flue. Use tur- bulator extractor 2.

  • Page 39: Checking The Water Chamber For Deposits

    Commissioning, inspection, maintenance Closing and securing the inspection ports Fig. 14 Fig. 15 Fit in reverse order to the description on page 36 "Removing the inspection port closures". Tightening torque approx. 20 Nm. Checking the water chamber for deposits 1. Fully drain the boiler. 3.
  • Page 40 Commissioning, inspection, maintenance Checking the tightness of the inspection ports (cont.) Fig. 16 Caution - hot surface! Headhole Inspection ports Manhole Handhole Note If the optional thermal insulation is fitted, this must first be removed. Checking the water level and system pressure See page 12ff.

  • Page 41: Adjusting The Burner

    Commissioning, inspection, maintenance Adjusting the burner The combustion heating output of the burner must not Information on the use of low-NO burners exceed the permissible combustion heating output of Incorrectly adjusted low-NO burners increase the lev- the boiler. Adjust the maximum gas or oil throughput of els of vibration and resonance during operation.
  • Page 42 Commissioning, inspection, maintenance Adjusting the burner (cont.) Calculating factor f 0.765 0.755 0.745 0.735 0.725 0.715 0.705 0.695 0.685 0.675 Operating pressure in bar Fig. 17 M75C With ECO 2 With ECO 1 Without ECO Calculating the combustion heating output Combustion heating output in kW = factor f x nominal steam mass flow rate in kg/h Example: Nominal steam...
  • Page 43 Commissioning, inspection, maintenance Adjusting the burner (cont.) Flame tube temperature monitoring (FTM) Furthermore, additional monitoring of the operating In line with the requirements of EN 12953-3, flame conditions is required if the flame tube clearance diam- tube temperature monitoring (FTM) is necessary under eter for smooth pipes or the average flame tube diam- the following conditions: eter for corrugated pipes is...
  • Page 44 Commissioning, inspection, maintenance Adjusting the burner (cont.) Boiler size 23 bar mbar 10.0 10.5 Without ECO 5 bar mbar 11.3 11.2 ■ 23 bar mbar 11.5 10.8 11.7 13.8 13.7 Type M75C Boiler size Nominal steam mass flow rate for operation with natural gas Nominal steam mass flow rate for operation with light fuel oil (HEL)
  • Page 45 Commissioning, inspection, maintenance Adjusting the burner (cont.) Boiler size 23 bar mbar 10.0 11.4 12.2 11.8 12.6 13.8 Without ECO 5 bar mbar 10.1 11.2 12.2 12.0 11.3 13.1 11.6 ■ mbar 11.9 13.2 14.4 14.1 13.4 15.4 13.6 23 bar Type M75C - continued Boiler size Nominal steam mass flow rate for...
  • Page 46 Commissioning, inspection, maintenance Adjusting the burner (cont.) Boiler size With ECO 1 5 bar mbar ■ mbar 10.3 23 bar Without ECO 5 bar mbar ■ 23 bar mbar 10.2 Type M93B Boiler size Nominal steam mass flow rate 1.65 Flame tube dimensions Diameter Smooth pipe, int.
  • Page 47 Commissioning, inspection, maintenance Adjusting the burner (cont.) Type M95B Boiler size Nominal steam mass flow rate for operation with natural gas Nominal steam mass flow rate for operation with light fuel oil (HEL) Flame tube dimensions Diameter Smooth pipe, int. 1056 1106 1156...
  • Page 48 Commissioning, inspection, maintenance Adjusting the burner (cont.) Type M95B - continued Boiler size Nominal steam mass flow rate for operation with natural gas 31.5 Nominal steam mass flow rate for operation with light fuel oil (HEL) 18 18.5 18.7 23.6 24.4 24.4 Flame tube dimensions...
  • Page 49 Commissioning, inspection, maintenance Adjusting the burner (cont.) Note For boiler size C and above, with or without ECO, the permissible combustion heating output is limited to 18 MW with EL fuel oil in accordance with EN 12953-3. Fig. 18 Flame tube dimensions Note Adjust the maximum oil/gas throughput of the burner to suit the required maximum combustion heating output...
  • Page 50 Commissioning, inspection, maintenance Adjusting the burner (cont.) Type M93B Boiler size Flue gas volume With ECO 2 m³ 1.66 1.86 2.43 2.72 3.31 3.97 4.74 ■ With ECO 1 m³ 1.69 1.90 2.48 2.77 3.37 4.04 4.83 ■ Without ECO m³...

  • Page 51: Troubleshooting

    Troubleshooting Diagnosis Fault/ System char- Cause of fault Measure acteristics Burner does not start. No voltage present. Switch ON the mains isolator. Safety chain activated. Check safety equipment. Burner fault indicator illuminates. Press reset button on the burner control unit. Fuel supply is interrupted.
  • Page 52 Wearing parts Wearing parts and gaskets Fig. 19 Ordering information Enter the serial no. of the boiler, the type and amount required. Obtain commercially available parts from your local trade supplier. Order forms Serial no.: Vitomax HS, type M73 size Pos.

  • Page 53: Wearing Parts And Gaskets

    Wearing parts Wearing parts and gaskets (cont.) Vitomax HS, type M73 size Pos. Component Quan- Quan- Quan- Quan- Quan- Quan- Quan- Quan- Quan- tity tity tity tity tity tity tity tity tity Seal ring set Headhole gasket 225 x 325 mm Serial no.: Vitomax HS, type M75 size Pos.
  • Page 54 Wearing parts Wearing parts and gaskets (cont.) Vitomax HS, type M93 size Pos. Component Quanti- Quanti- Quanti- Quanti- Quanti- Quanti- Quantity Insulation ring (optional) Burner connection packing Cleaning cover packing Rear boiler floor packing Packing per inspection port Handhole gasket 100 x 150 mm Manhole gasket 325 x 425 mm Seal ring set Headhole gasket 225 x 325 mm...
  • Page 55 Checklist Recommendations for operation, maintenance and testing in accordance with EN 12953-6 Checklist for boiler system: Steam boiler O = Monitoring, check for unusual noises, odours, smells, other unusual phenomena ■ ■ T = Function check on equipment components, including monitoring Operation, maintenance and inspec- Months Type of tests (examples)
  • Page 56 Checklist Suggested tests and test intervals Note The extent of inspections and time intervals are manu- facturer's recommendations. As part of the commis- sioning, these should be matched to the individual sys- tem as part of the arrangements made with the system user, the supervisory authority and the manufacturer.
  • Page 57 Appendix Steam and hot water boilers Boiler type: Boiler output: Serial no.: Month: Year: Inspection checklist Operating Safety Pressure Pressure Flue gas Flue gas Flame ap- Combustion pressure valve regulator limiter heat ex- damper pearance system changer...
  • Page 58 Appendix Steam and hot water boilers (cont.) Pressure Water level Water level High water Feedwater T.D.S. facili- Blow-down gauge indicator limiter level pump valve Comments/faults: Signatures: Boiler techni- Line manager cians Scope and interval of test according to table on page 55...

  • Page 59: Inspection Checklist

    Appendix Water treatment system Steam generating system: Month: Year: Inspection checklist Feedwater Electrical Temperature Appearance pH value at Residual Oxygen bind- Residual conductivity 25 °C oxygen hardness at 25 °C S/cm °C mg/l mg/l mmol/l µ...
  • Page 60 Appendix Water treatment system (cont.) Top-up water Condensate Boiler water Residual Electrical pH value at Residual Electrical pH value at Excess Acid capaci- hardness conductivi- 25 °C hardness conductivi- 25 °C phosphate ty (K S 8.2 ty at 25 °C ty at 25 °C mmol/l S/cm...
  • Page 61 Commissioning/service reports Records of commissioning, inspection and maintenance Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date:...
  • Page 62 Keyword index Keyword index Ammonia..............17 Low-NOx burner............41 – "Hard flame"............41 Blow-down..............12 Boiler, filling..............26 Multi boiler system............. 25 Boiler door..............35 Multi-boiler system............. 17 Boiler filling..............11 Boiler idle time............28 Boiler water..............40 Nitrogen..............15, 17 Boilout................ 28 NW electrode..............11 Burner..............

  • Page 63: Keyword Index

    Keyword index Keyword index (cont.) Water level limiter............26 Water side connections..........39 Water quality.............. 19 Water side preservation..........17 Water shortage............11 Wet preservation..........15, 16 Water side closures............28...
  • Page 64 Represented by Manufacturer Viessmann Ltd Viessmann Industriekessel Mittenwalde GmbH Hortonwood 30 Berliner Chaussee 3 TF1 7YP Telford D-15479 Mittenwalde Telephone: +441952 675000 Telephone: +49 33764 83-0 Telefax: +441952 675040 Telefax: +49 33764 83-202 www.viessmann.co.uk www.viessmann.com...

This manual is also suitable for:

Vitomax hs m75Vitomax hs m93Vitomax hs m95

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