Viessmann VITOMAX 200-HS Training manual

Operating and service
instructions
for contractors
VIESMANN
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
5607 288 GB 9/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
Viessmann Industrieservice, the sys-
tem installer or a qualified person
authorised by the installer.
Regulations
Observe the following when working on
this system
■ All legal instructions regarding the pre-
vention of accidents
■ All legal instructions regarding envi-
ronmental protection
■ Health and Safety at Work Act (Betr-
SichV) [Germany]
■ The Code of Practice of relevant trade
associations
■ Directive 97/23/EC, as well as the rel-
evant safety regulations of the follow-
ing countries
dDVGW, TRGI, TRF and VDE,
TRD
aKG, ABV, LRG-K, LRV-K, DKBG
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
If you notice oil leaks and the smell of
gas
Danger
Escaping fuel can lead to explo-
sions which may result in very
serious injuries.
■ Do not smoke. Prevent naked
flames and sparks. Do not
switch lights or electrical appli-
ances on or off.
■ Close the quick-acting fuel
valve and shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5607 288 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shutdown system.
■ Ventilate boiler room.
Working on the system
■ Close the fuel shut-off valve and
secure against unintentional opening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as water
pipes, to discharge static loads.
Danger
Risk of burning from hot surfaces
so that
■ steam line,
■ hot water line,
■ cleaning cover and closures/
plugs at the boiler system,
■ boiler doors, as well as compo-
nents behind the doors,
can all become very hot. Observe
safety in the workplace!
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Draining hot water
!Please note
The blow-down and T.D.S. water
from boiler systems can reach
temperatures of 100 °C and
higher.
Set up the system so that this
water is cooled down to < 35 °C
prior to it entering the sewer sys-
tem. Where necessary, refer to
the local water authority.
Safety instructions
Safety instructions (cont.)
5607 288 GB

4
Draining condensate from the flue
gas side
!Please note
When the boiler system starts or
under certain conditions, conden-
sate can form in the flues, the flue
gas collector and downstream in
the flue or chimney.
The system user must provide
suitable installations to safely
drain such condensate.
Subject to the regulations in the country
concerned, this condensate may need to
be neutralised. In such cases, consult
the local water authority or the relevant
body responsible for issuing permits.
Technical safety information
Any damage to the boiler that could
lead to risks requires an immediate
boiler shutdown.
If major damage occurs at the boiler or
vessels, notify the authorising supervi-
sory body without delay prior to carrying
out repairs.
Observe all technical safety instructions.
Steam generators require local permits
both for their installation and their oper-
ation. This permit must be available prior
to commissioning.
In the case of explosions, the user must
immediately notify the authorising super-
visory body, irrespective of whether any-
one was injured or not. Prior to the official
investigation, the status created by the
accident must not be changed apart from
what is necessary to prevent further
damage or as required for rescuing per-
sonnel.
The boiler house must only be entered
by authorised personnel. Always keep
the boiler house clean, well lit and free
from all objects that do not belong there
and that might impair the operation. The
use of any part of the system as a drying
area is prohibited.
During operation, all required exits must
be left unlocked and free from obstruc-
tions. The operating personnel must log
all events, such as faults, adjustments,
consumption of spare parts and repairs.
A log must be maintained of all regular
readings of the control instruments.
Safety instructions
Safety instructions (cont.)
5607 288 GB

5
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. Protect all
boiler parts and control equipment from
rain, water leaks and expelled steam.
Immediately repair all damage and
leaks.
Apart from the relevant legal require-
ments, all practical instructions issued by
our technical personnel to the operating
personnel are applicable.
It is impossible to clarify and describe all
potential cases of indicators and possi-
ble faults. These guidelines should
therefore, after a reasonable time in
operation, be supplemented based on
the experiences gained up to that point.
Safety instructions
Technical safety information (cont.)
5607 288 GB

6
Operating instructions
Operating information
Storage of Vitomax boilers prior to installation as part of the system................... 7
Operating tips....................................................................................................... 7
Functions.............................................................................................................. 9
Shutting down the system.................................................................................... 17
Preservation......................................................................................................... 17
Maintenance instructions...................................................................................... 21
Service instructions
Water quality
Water quality for steam boiler systems................................................................ 22
Commissioning
Preamble.............................................................................................................. 31
Installation............................................................................................................ 31
Commissioning..................................................................................................... 33
Utilisation and operation
Monitoring............................................................................................................. 40
What to do in case of operating faults.................................................................. 41
Repairs and inspection
Repairs................................................................................................................. 42
Inspection............................................................................................................. 43
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 44
Further details regarding the individual steps....................................................... 45
Spare parts
Wearing parts, gaskets......................................................................................... 56
Appendix
Operating, maintenance and inspection tasks..................................................... 59
Keyword index.................................................................................................... 61
Index
Index
5607 288 GB

7
Please note:
This information applies to the storage prior to the system installation.
1. Vitomax boilers must be stored in
enclosed rooms, free from weather
influences under dry conditions.
2. The room temperature must not fall
below 0 °C nor exceed +50 °C.
3. In its delivered condition the boiler is
protected as standard on the water
side with dummy flanges or caps
against the ingress of foreign matter.
4. Remove the shipping packaging to
prevent the formation of condensate.
To prevent corrosion in the non-pressur-
ised state, observe the following if the
boiler is stored for longer than 4 weeks:
■ Protect the interior of the boiler against
moisture on the flue gas side and on
the DHW side with a desiccant, e.g.
silica gel.
■ The amount of desiccant depends on
the boiler volume.
■ Check the effectiveness of the desic-
cant regularly. See the details provi-
ded by the desiccant manufacturer.
■ Ensure that the desiccant does not
come into contact with the boiler mate-
rial (e.g. through suspended fixing).
■ Preserve the dry flue gas side with a
thin film of graphite or boiled oil.
■ Instead of the moisture extraction on
the flue gas side by means of a desic-
cant; a dryer with air circulation can
also be connected.
Operating tips
According to the Steam Boiler Order
[Germany], a steam boiler category IV
may only be taken into use when the rel-
evant authority has granted permission
for the installation of the system, and an
authorised expert has tested the sys-
tem.
According to the Steam Boiler Order
[Germany], steam boilers category IV
may only be operated, supervised and
maintained by a trained boilerman.
The approved inspection body may
grant, upon application, permission to
operate the boiler without supervision
subject to it being equipped in accord-
ance with the TRD 604.
The system must be commissioned by
the Viessmann Industrieservice, the sys-
tem installer or a qualified person author-
ised by the installer as well as the rele-
vant expert.
Within 4 weeks of the combustion equip-
ment being commissioned, the operator
must notify the local flue gas inspector
accordingly [check local regulations].
Operating information
Storage of Vitomax boilers prior to installation as part of the system
5607 288 GB
Operation

8
Record all actual values in a test report.
These must be confirmed by the instal-
ler, the relevant expert and the system
operator.
We would recommend that you operate
the boiler constantly at the required oper-
ating pressure. The operation of the
boiler at pressure will still be beneficial,
even if no heat demand occurs for a lon-
ger period of time.
In systems comprising several boilers, of
which one is constantly used as standby
boiler, only change the operation over
after longer intervals, e.g. during the
annual inspection of the total system.
Operating information
Operating tips (cont.)
5607 288 GB

9
Installation drawing
rZ6 2 wT wZ
wO
wU
qT
rP
wI
qQqWqPqEqW wQ wW wP
rT
4
eQ
3
5
rQrWrR rErR 1
wE
wR
qR
Illustrative example. Order-specific deviations from the standard delivery are possi-
Operating information
Functions
5607 288 GB
Operation

10
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.
1Platform
2Control panel
See separate documentation
3Integral economiser
4Connection line between econo-
miser and boiler
5Feedwater pump (module)
6Burner
qP Level electrode
(WR – water level control)
qQ Level electrode
(HW – maximum water level)
qW Level electrode
(NW – minimum water level)
qE Accessory, flanged connection
DN 100
qR Accessory, flanged connection
DN 100
qT Conductivity electrode
wP Safety valve
wQ Air vent shut-off valve
wW Steam shut-off valve
wE Feedwater shut-off valve
wR Feedwater non-return valve
wT Blow-down shut-off valve
wZ Blow-down valve
wU T.D.S. shut-off valve
wI T.D.S. valve
wO Mating flange DN 20
eQ Air vent valve for economiser
rP Water level indicator
rQ Pressure gauge
rW Maximum pressure limiter
rE Pressure transducer
rR Straight-through shut-off valve with
cap (option)
rT Dial thermometer
rZ Sampling cooler
In the following, selected components of
a steam boiler system are described. For
details, see the documentation provided
by the manufacturer of the individual
components.
Operating information
Functions (cont.)
5607 288 GB

11
Level electrodes qP to qW
Permanently modulating level monitoring qP
Level electrode for continual and load-dependent boiler filling
Function Method of opera-
tion
Operating information
Continual water level con-
trol comprising
■ A level electrode
■ An associated level
controller
Water level below or
exceeds the selec-
ted set value
The controller issues a pulse to the
feedwater control valve
Boiler is filled continually and sub-
ject to load
Continual control of the
boiler water level via the
feedwater control valve
Operating information
Functions (cont.)
5607 288 GB
Operation

12
Level monitoring water level "too high" (HW electrode qQ)
Level electrode to safeguard against maximum water levels
Function Operating condi-
tion
Operating informa-
tion
Self-monitoring overfill protection
comprising
■ A level electrode
■ The associated evaluating device
Standard water
level
Electrode is not
immersed in the con-
ducting boiler water
and registers a high
resistance
Feedwater pump oper-
ation enabled
Feedwater pump runs
Boiler is filled continu-
ally and subject to load
Water level too
high
Electrode is immersed
into the boiler water and
registers a low resist-
ance
The feedwater pump is
stopped via the pump
relay
Feedwater supply to
the boiler interrupted
The level drops
again
Feedwater pump can
start subject to
demand
Note
See also country-specific regulations.
Operating information
Functions (cont.)
5607 288 GB

13
Level monitoring water level "too low" (NW electrode qW)
Level electrode to safeguard against minimum water levels
Function Operating condi-
tion
Operating informa-
tion
Self-monitoring low water indicator
comprising
■ Two level electrodes
■ The associated evaluating devices
Standard water
level
Electrode is immersed
into the conducting
boiler water and regis-
ters a low resistance
Safety chain closed
Burner operation ena-
bled
Water level too low Electrode is out of the
boiler water and regis-
ters a high resistance
Safety chain and
burner operation con-
stantly interrupted
The minimum boiler
water content is
achieved again
Re-enable safety chain
Burner block lifted
Safety valve wP
Function
■ Physical protection of the boiler
against pressures in excess of the
max. permissible operating pressure
P1
■ Valve response pressure = max. per-
missible steam boiler operating pres-
sure
■Valve discharge capacity ≥ max.
steam output (boiler)
■ Pressure increase max. P1 plus 10%
with max. blow-off rating
■ Closing pressure at P1 minus 10 %
Testing/checks Operating information
Operating checks in regular intervals or
in accordance with country-specific
regulations
Briefly cracking open by lifting the lever –
Do not release the lever.
Note the manufacturer’s operating instruc-
tions
Regular checking by an authorised con-
tractor or test body
Never remove the lead seal
Operating information
Functions (cont.)
5607 288 GB
Operation

14
Air vent shut-off valve wQ
Function Operation Operating information
Venting the boiler
during filling or
after a new sys-
tem start from
atmospheric
pressure
During heat-up,
open the valve and
close it again, as
soon as visible
steam is expelled
Air / steam must be able to be routed away
safely
Steam shut-off valve wW
Function Operation Operating information
Main boiler shut-
off towards the
steam mains
Enable steam or
close boiler with
damper valves
Open slowly to prevent water hammer
Blow-down wT and wZ
Function
■ Periodic removal of sludge deposits
Method of operation Operating information
Automatic blow-down via programma-
ble valve at regular intervals
The programmable switch opens via the
control valve of the blow-down valve and
briefly drains off boiler water. The vacuum
force thus created removes the sludge from
the boiler
Manual activation possible at any time
Manual blow-down at regular intervals
or in accordance with country-specific
regulations
Push the locking lever of the blow-down
valve to the side
Push down on the activating lever of the
blow-down valve for two to three seconds
Please note
When acting manually, be mindful of the
lever kickback
!Please note
When acting manually, be mind-
ful of the lever kickback
Operating information
Functions (cont.)
5607 288 GB

15
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 Flow rate is reduced
Conductivity value exceeds the selec-
ted set value
Valve is opened further
Conductivity exceeds the highest
value
Safety chain is opened
Burner stops
Water level indicator rP
Function
■ Visual and direct water level indication
Method of operation Operating information
Visual water level check Valve on the steam and water side; shut-off
device OPEN
Flushing valve, shut-off device CLOSED
When there are no personnel present Keep valve CLOSED
Carry out operating checks at regular
intervals or in accordance with country-
specific regulations
Close the valve on the water and steam
side
Open blow-down valve, drain and check the
valve for tightness
Open the valve on the water side; check for
discharge noise
Close valve on the water side
Open the valve on the steam side; check for
discharge noise
Leave the valve on the steam side open
Close the flushing valve
Open valve on the water side
The water column rises quickly to the
correct level
When the water column rises slowly, check
that there are no blockages
Operating information
Functions (cont.)
5607 288 GB
Operation

16
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
indicator
Operating checks at regular intervals
or in accordance with country-specific
regulations
■Pressure limiter rW Protection of the
boiler against over-
pressure when the
maximum pressure
is exceeded
Checking with a calibrated test pres-
sure gauge by an authorised contrac-
tor or test body
Safety chain opened by opening a
contact in the pressure limiter
Burner stops
Safety chain reset by means of the
appropriate key in the control panel.
Reduce the boiler pressure via the air
vent valve or the main steam valve by
approx. 1 bar below the switching
point of the max. pressure limiter and
reset the max. pressure limiter
Burner starts again
■ Pressure trans-
ducer rE
Load-dependent reg-
ulation of the boiler
combustion subject
to the operating pres-
sure
■ Straight-through
shut-off valve with
cap rR
Enables the replace-
ment of faulty com-
ponents
Exclusively by authorised contractors
Operating information
Functions (cont.)
5607 288 GB

17
Sampling cooler rZ
Function Operating information
Removal of water samples to carry out
comparative tests
Values to be checked in accordance with
country-specific regulations and to be
recorded in the boiler log
■ pH value
■ Residual hardness
■ p value (value to determine the free alka-
linity)
■ m value (value to determine the entire
alkalinity)
■ Phosphate
■ Sulphite
Shutting down the system
For short interruptions ≤ 3 days, maintain
the positive pressure in the boiler system
incl. all boiler-related drives (thermal
water treatment etc.). See also
page 38.
For longer interruptions, see chapter
"Preservation".
Preservation
The procedures listed in the following
should be considered as preservation
options. Further procedures with alter-
native chemicals should be agreed with
their manufacturer. The basis of these
instructions is the VdTÜV datasheet
TC1465 "Preserving the water side of
steam boilers" [Germany].
To prevent corrosion setting in during
idle periods when the boiler is not pres-
surised, preserve the boiler surfaces on
the flue gas and water sides subject to
the length of the period during which the
boiler is taken out of use. There is a dif-
ferentiation between wet preservation
during which exposure to oxygen is to be
avoided and dry preservation during
which moisture levels are to be mini-
mised.
Operating information
Functions (cont.)
5607 288 GB
Operation

18
Wet preservation
1. Fill the boiler incl. economiser (if
installed) up to the highest possible
level with treated feedwater. To pre-
vent oxygen corrosion, add an oxygen
binder to the boiler water (e.g. sodium
sulphite) in accordance with the man-
ufacturer's instructions. For this,
ensure good admixing with the boiler
water (thermal or mechanical agita-
tion).
2. In multi boiler systems if only some
boilers must be preserved, these can
be filled with desalinated boiler water
from the boilers that remain in use.
This will also maintain the tempera-
ture. Ensure that the temperature
remains constant.
3. Maintaining pressure in a fully filled
boiler using nitrogen (preferably nitro-
gen 5.0) of 0.1 to 0.2 bar can prevent
boiler corrosion.
Chemical wet preservation chemically
binds the oxygen thereby protecting the
boiler material against corrosion. The
chemical wet preservation can be imple-
mented when steam boilers are taken
out of use for short or longer periods.
An adequate amount of oxygen binders,
corresponding putrefaction by alkalis, a
thorough mixing of the preservation sol-
ution and complete filling of the boiler or
system, effectively prevent corrosion
due to idle periods whilst giving a great
deal of security with a reasonable
amount of effort and cost.
Never use this procedure where there
is a risk of frost.
Apart from the chemical wet preserva-
tion, physical-technical methods may
also be applied. With the wet preserva-
tion, the rapid boiler availability is an
advantage.
Preservation with sodium sulphite
For steam boilers, add the sodium sul-
phite in soluble form to the completely
drained steam boiler via the feedwater
pump. Fill the steam boiler completely.
Also fill any installed economisers. The
pH value should be between 11 and 12.
Keep all valves closed during the pres-
ervation process. The preservation sol-
ution should be circulated weekly. Ini-
tially, check the sulphite excess fre-
quently, then at least once monthly.
When the content drops and falls below
the specified standard values, recircu-
late again and add agent, as required.
Operating information
Preservation (cont.)
5607 288 GB

19
Sodium sulphite excess
Idle time Sodium sulphite con-
tent in the preserva-
tion solution mg
Na2So3/l
Additional sodium sul-
phite
Without
water g/m3
Crystal-
lised g/m3
Fill water for steam
boilers:
■ Water of low salt
content
1 week 20 - 50 20 - 50 40 - 100
■ Fully desalinated
water
1 month 100 - 200 100 - 200 200 - 400
■ Condensate Longer
than 1
month
200 - 500 200 - 500 500 - 1000
■ Water with salt
content
e.g. fully softened
water
1 week 40 - 100 40 - 100 80 - 100
or boiler water Longer
than 1
week
400 - 1000 400 - 1000 800 - 2000
When using cold-prepared water which has not been deaerated, add an additional
80 g (without water) or 160 g (crystallised) sodium sulphite per m3.
Preservation with film forming
amines
A wet preservation with film forming
amines is not permissible.
Note
■ Observe all conditions for draining
waste water into sewer systems or into
the main discharge system when
draining the preserving solution.
■ When using the preserving agents,
observe the working instructions and
safety datasheets supplied by the
product manufacturer.
■ Also agree the steps for the preserva-
tion of the water side with the manu-
facturer of the preserving agent.
Preservation through physical-tech-
nical measures
The following preservation steps through
physical-technical processes are also
possible, such as
■ Maintaining a positive steam pressure
in the boiler
■ Flow preservation of steam boilers.
These processes require system-spe-
cific equipment (valves, pipework,
pumps) and should be taken into con-
sideration when designing the system.
Operating information
Preservation (cont.)
5607 288 GB
Operation

20
Dry preservation
Note
This method is used when longer idle
periods are expected and to ensure pro-
tection against frost. This method means
that a quick return of the system into use
is not possible.
Complete drying out
After cooling down in the idle stage, the
boiler will be quickly drained at a pres-
sure of approx. 3 bar. Observe the max-
imum permissible temperature for drain-
ing into the public sewage system.
Where required, catch the water in a col-
lecting tank and drain it after it has
cooled down sufficiently.
Flush steam boilers with a high salt con-
tent in their boiler water (> 5 000 µS/cm)
once more on the water side. Afterwards,
open all man, head and hand holes.
Dry out components, such as econo-
misers, separately.
Position desiccants (e.g. silica gel, blue
gel) in shallow bowls inside the open and
drying boiler or hang them inside the
boiler so that any contact with the boiler
material is safely prevented. Then close
the boiler. Check the desiccants at least
monthly. They should be replaced as
and when required.
Preservation with ammonia or nitro-
gen
These methods require extensive tech-
nical and technological effort. When
using these preserving methods, formu-
late system-specific operating instruc-
tions.
Preserving the hot gas side
Flue gas side
After the boiler has been taken out of
use, clean the heating surfaces on their
hot gas side. The normal draught
ensures that the heating surfaces on the
hot gas side are adequately dried. Accel-
erate the process by means of a fan
heater; if required open the flue gas shut-
off dampers for this process and then
close again.
It is recommended to treat the combus-
tion chamber and the hot gas flues with
preserving oil (graphite or boiled oil).
This can be sprayed on or applied with a
brush. The boiler doors remain open.
Keep the surfaces dry during idle periods
(by adding a desiccant such as silica gel
or by air circulation via a connected
dryer).
A dry preservation is not recommended
under special installation conditions in
areas with high relative humidity (in the
tropics, near the sea).
Operating information
Preservation (cont.)
5607 288 GB